MAINTENANCE MANUAL - Babin Machine › PDF › Hardinge HLV-H Maintenance... · 2016-05-04 · MAINTENANCE MANUAL Hardinge High Speed Super-Precision ® HLV ®-H Toolroom and TFB

MAINTENANCE MANUAL

Hardinge High Speed Super-Precision®

HLV®-H Toolroom and TFB®-H Production Lathes

This maintenance manual applies to machineswith serial number 13585 or higher.

- CAUTION -

Use petroleum base cutting fluids only! Use of water base coolants will voidthe warranty.

Revised: June 26, 2007

Manual No. M-10C Litho in U.S.A.Part No. M C-0009500-0010 February, 1991

TP4327HLV machine with optional Acu-Rite® III digital readout

- NOTICE -Damage resulting from misuse, negligence, or accident is not covered by theHardinge Machine Warranty.

Information in this manual is subject to change without notice.

This manual covers the maintenance of the Hardinge High SpeedSuper-Precision® HLV®-H Toolroom and TFB-H® Production Lathes.

In no event will Hardinge Inc. be responsible for indirect or consequentialdamages resulting from the use or application of the information in this man-ual.

Reproduction of this manual, in whole or in part, without written permissionof Hardinge Inc. is prohibited.

CONVENTIONS USED IN THIS MANUAL

- WARNING -Warnings must be followed carefully to avoid the possibility of personal in-jury or damage to the machine, tooling, or workpiece.

- CAUTION -Cautions must be followed carefully to avoid the possibility of damage to themachine, tooling, or workpiece.

- NOTES -Notes contain supplemental information.

Hardinge Inc.One Hardinge Drive

P.O. Box 1507Elmira, New York 14902-1507

Telephone: 607-734-2281 Fax: 607-734-8819www.hardinge.com

©1991, Hardinge Inc. M-10C

READ COMPLETE INSTRUCTIONS CAREFULLYBEFORE OPERATING MACHINE

When this instruction book was printed, the information given was current. However, since we areconstantly improving the design of our machine tools, it is possible that the illustrations anddescriptions may vary from the machine you received.

- WARNING -Occupational Safety and Health Administration (OSHA) Hazard Communica-tion Standard 1910.1200, effective May 25, 1986, and various state “employeeright-to-know laws” require that information regarding chemicals used withthis equipment be supplied to you. A complete list of the chemicals usedwith this machine, their reference data sheet numbers, and their suppliersappears as an insertion at the end of this manual. Refer to the applicablesection of the Material Safety Data Sheets supplied with your machine whenhandling, storing, or disposing of chemicals.

HARDINGE SAFETY RECOMMENDATIONS

Your Hardinge machine is designed and built for maximum ease and safety of operation.

However, some previously accepted shop practices may not reflect current safety regulations andprocedures, and should be re-examined to insure compliance with the current safety and healthstandards.

Hardinge recommends that all shop supervisors, maintenance personnel, and machine tooloperators be advised of the importance of safe maintenance, setup, and operation of Hardinge-builtequipment. Our recommendations are described below. READ THESE SAFETYRECOMMENDATIONS BEFORE PROCEEDING ANY FURTHER.

READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation ormaintenance of the machine. Make sure you understand all instructions.

CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job.

DON’T OPERATE EQUIPMENT unless proper maintenance has been regularly performedand the equipment is known to be in good working order.

DON’T REMOVE any warning or instruction tags from machine.

DON’T OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibrationoccurs. Report any excessive or unusual vibration, sounds, smoke, or heat as well as anydamaged parts.

MAKE SURE equipment is properly grounded. Consult National Electric Code and all localcodes.

DISCONNECT MAIN ELECTRICAL POWER before attempting repair or maintenance.

DON’T REACH into any control or power case area unless electrical power if OFF.

(continued on the next page)

M-10C i

DON’T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on awet surface.

ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing elec-trical equipment.

DON’T ALLOW the operation or repair of equipment by untrained personnel.

REPLACE BLOWN FUSES with fuses of the same size and type as originally furnished.

ASCERTAIN AND CORRECT cause of a shutdown caused by overload heaters beforestarting machine.

WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times. When neces-sary, wear respirator, helmet, gloves and ear muffs or plugs.

KEEP AREA THE AROUND THE MACHINE well lighted and dry.

KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating equip-ment.

HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combusti-ble material and keep chips clear of the work area.

DON’T USE a toxic or flammable substance as a solvent cleaner or coolant.

MAKE SURE PROPER GUARDING is in place and all doors are closed and secured.

DON’T ALTER THE MACHINE to bypass any interlock, overload, disconnect or othersafety device.

MAKE SURE chucks, closers, fixture plates, and all other spindle-mounted work-holdingdevices are properly mounted and secured before starting machine.

MAKE CERTAIN all tools are securely clamped in position before starting machine.

REMOVE ANY LOOSE PARTS OR TOOLS left on machine or in the work area before op-erating machine. Always check machine and work area for loose tools and parts, especiallyafter work has been done by maintenance personnel.

REMOVE CHUCK WRENCHES before starting the machine.

KNOW WHERE ALL stop pushbuttons are located in case of an emergency.

CHECK THE LUBE LEVEL before operating the machine.

INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in goodcondition and are functioning properly before operating the machine.

CHECK THE TURRET POSITION before initiating carriage/cross slide motion.

CHECK SETUP, TOOLING, AND SECURITY OF WORKPIECE if the machine has beenOFF for any length of time.

ii M-10C

MAKE CERTAIN you are clear of any “pinch point” created by moving slides before startingthe machine.

DON’T OPERATE any equipment while any part of the body is in the proximity of a poten-tially hazardous area.

DON’T REMOVE CHIPS with hands. Use a hook or similar device and make certain thatall machine movements have ceased.

BE CAREFUL of sharp edges when handling newly machined workpieces.

DON’T REMOVE OR LOAD workpieces while any part of the machine is in motion.

DON’T OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing,neckties or long hair not contained by a net or shop cap.

DON’T ADJUST tooling or coolant hoses while the machine is running.

DON’T LEAVE tools, workpieces or other loose items where they can come in contact witha moving component of the machine.

DON’T CHECK finishes or dimensions of workpiece near running spindle or moving slides.

DON’T ROTATE SPINDLE in either direction when checking threads with a thread gage.

DON’T ATTEMPT to brake or slow the machine with hands or any makeshift device.

ANY ATTACHMENT, TOOL, OR MACHINE MODIFICATION not obtained from HardingeInc., must be reviewed by a qualified safety engineer before installation.

USE CAUTION around exposed mechanisms and tooling especially when setting up. Becareful of sharp edges on tools.

DON’T USE worn or defective hand tools. Use the proper size and type for job beingperformed.

USE ONLY a soft-faced hammer on turret tools and fixtures.

DON’T USE worn or broken tooling on machine.

MAKE CERTAIN that all tool mounting surfaces are clean before mounting tools.

INSPECT ALL CHUCKING DEVICES daily to make sure they are in good operatingcondition.

REPLACE DEFECTIVE CHUCK before starting machine.

USE MAXIMUM ALLOWABLE gripping pressure on the chuck. Consider weight, shape andbalance of workpiece.

USE LIGHTER THAN NORMAL feedrates and depth of cut when machining a workpiecediameter that is larger than the gripping diameter.

(continued on the next page)

M-10C iii

DON’T EXCEED the rated capacity of machine.

DON’T LEAVE the machine unattended while it is operating.

DON’T CLEAN the machine with an air hose.

DON’T OVERFILL tote pans.

KEEP TOTE PANS a safe distance from machine.

DON’T LET STOCK project past the back end of the collet closer or machine spindle with-out being adequately covered and properly supported.

USE FEED TUBE BUSHINGS when using a bar feed.

MAKE CERTAIN that any bar feed mechanism is properly aligned with spindle. If floor-mounted type, it must be securely bolted to floor.

FOR YOUR PROTECTlON - WORK SAFELY

iv M-10C

Table of Contents

Hardinge Safety Recommendations . . . . . . . . . . . . . i

CHAPTER 1 - CARRIAGECarriage Apron Disassembly . . . . . . . . . . . . . . . . 1-1Carriage Apron Reassembly . . . . . . . . . . . . . . . . 1-8Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . 1-10Carriage Lock . . . . . . . . . . . . . . . . . . . . . . . 1-10

Removal . . . . . . . . . . . . . . . . . . . . . . . . 1-10Replacement . . . . . . . . . . . . . . . . . . . . . . 1-11

Gear Rack . . . . . . . . . . . . . . . . . . . . . . . . 1-12Removal . . . . . . . . . . . . . . . . . . . . . . . . 1-12Replacement . . . . . . . . . . . . . . . . . . . . . . 1-14Lubrication . . . . . . . . . . . . . . . . . . . . . . . 1-15

Gib Adjustment . . . . . . . . . . . . . . . . . . . . . . 1-16Handwheel . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Removal . . . . . . . . . . . . . . . . . . . . . . . . 1-17Disassembly . . . . . . . . . . . . . . . . . . . . . . 1-17Reassembly . . . . . . . . . . . . . . . . . . . . . . 1-18Replacement . . . . . . . . . . . . . . . . . . . . . . 1-18Clearance Adjustment. . . . . . . . . . . . . . . . . . 1-19

Lead Screw (HLV®-H Machines Only) . . . . . . . . . . . . 1-19Removal . . . . . . . . . . . . . . . . . . . . . . . . 1-19Replacement . . . . . . . . . . . . . . . . . . . . . . 1-21Lubrication . . . . . . . . . . . . . . . . . . . . . . . 1-21

Lead Screw Nut (HLV-H Machines Only) . . . . . . . . . . 1-22Removal . . . . . . . . . . . . . . . . . . . . . . . . 1-22Replacement . . . . . . . . . . . . . . . . . . . . . . 1-24Lubrication . . . . . . . . . . . . . . . . . . . . . . . 1-26

Carriage Lubrication System . . . . . . . . . . . . . . . . 1-27Replacing an Oil Feed Tube Metering Unit . . . . . . . . 1-27Operating the Lubricator. . . . . . . . . . . . . . . . . 1-33Filling the Lubricator Reservoir. . . . . . . . . . . . . . 1-33

Chapter 2 - Cross Slide and Tool PostCross Slide Feed Screw . . . . . . . . . . . . . . . . . . 2-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . 2-1Reassembly . . . . . . . . . . . . . . . . . . . . . . 2-2

Cross Slide Feed Screw Nut Adjustment . . . . . . . . . . 2-3Cross Slide . . . . . . . . . . . . . . . . . . . . . . . . 2-4


Cross Slide Gib Adjustment. . . . . . . . . . . . . . . . . 2-5Tool Post . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Tool Post Slide Disassembly . . . . . . . . . . . . . . 2-6Tool Post Slide Reassembly . . . . . . . . . . . . . . . 2-8Tool Post Slide Feed Screw Nut Adjustment . . . . . . . 2-12Tool Post Slide Lubrication . . . . . . . . . . . . . . . 2-12Tool Post Slide Gib Adjustment . . . . . . . . . . . . . 2-13

M-10C v

Chapter 3 - Spindle and Power Feed DrivesSpindle Drive . . . . . . . . . . . . . . . . . . . . . . . 3-1

Checking Drive Belt Tension. . . . . . . . . . . . . . . 3-1Adjusting Drive Belt Tension. . . . . . . . . . . . . . . 3-2Motor and Spindle Belt Replacement. . . . . . . . . . . 3-3

Spindle Brake . . . . . . . . . . . . . . . . . . . . . . . 3-10Spindle Brake Gap Adjustment . . . . . . . . . . . . . 3-10Spindle Brake Insert Replacement . . . . . . . . . . . . 3-11Spindle Brake Insert Lubrication . . . . . . . . . . . . . 3-11

Speed Change Feed Screw Nut . . . . . . . . . . . . . . 3-12Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-12Replacement . . . . . . . . . . . . . . . . . . . . . . 3-13

Speed Change Mechanism . . . . . . . . . . . . . . . . . 3-14Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-14Disassembly . . . . . . . . . . . . . . . . . . . . . . 3-16Reassembly . . . . . . . . . . . . . . . . . . . . . . 3-19Replacement . . . . . . . . . . . . . . . . . . . . . . 3-20Lubrication . . . . . . . . . . . . . . . . . . . . . . . 3-22

Pulley and Shaft Assembly . . . . . . . . . . . . . . . . . 3-22Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-22Replacement . . . . . . . . . . . . . . . . . . . . . . 3-24

Power Feed Drive . . . . . . . . . . . . . . . . . . . . . 3-27Power Feed Control Panel . . . . . . . . . . . . . . . 3-27Power Feed Lubrication . . . . . . . . . . . . . . . . . 3-27Drive Disassembly . . . . . . . . . . . . . . . . . . . 3-27Drive Reassembly . . . . . . . . . . . . . . . . . . . 3-30Drive Motor Brush Replacement . . . . . . . . . . . . . 3-31

Chapter 4 - Gearbox and HeadstockCollet Closer. . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal and Cleaning . . . . . . . . . . . . . . . . . 4-1Replacement . . . . . . . . . . . . . . . . . . . . . . 4-2

Gearbox (English) . . . . . . . . . . . . . . . . . . . . . 4-2Lubrication . . . . . . . . . . . . . . . . . . . . . . . 4-2Gearbox Removal (English) . . . . . . . . . . . . . . . 4-3Gearbox Disassembly (English) . . . . . . . . . . . . . 4-6Gearbox Reassembly (English) . . . . . . . . . . . . . 4-13Gearbox Replacement (English) . . . . . . . . . . . . . 4-16

Gearbox (English-Metric) . . . . . . . . . . . . . . . . . . 4-18Lubrication . . . . . . . . . . . . . . . . . . . . . . . 4-18Gearbox Removal (English-Metric) . . . . . . . . . . . . 4-19Gearbox Disassembly (English-Metric) . . . . . . . . . . 4-20Gearbox Reassembly (English-Metric) . . . . . . . . . . 4-30Gearbox Replacement (English-Metric) . . . . . . . . . . 4-35

Gear Change Bracket (English) . . . . . . . . . . . . . . . 4-36Disassembly . . . . . . . . . . . . . . . . . . . . . . 4-36Reassembly . . . . . . . . . . . . . . . . . . . . . . 4-36

Gear Change Bracket (English-Metric). . . . . . . . . . . . 4-37Disassembly . . . . . . . . . . . . . . . . . . . . . . 4-37Reassembly . . . . . . . . . . . . . . . . . . . . . . 4-37

Gear Change Bracket Lubrication . . . . . . . . . . . . . . 4-38

vi M-10C

Headstock . . . . . . . . . . . . . . . . . . . . . . . . . 4-39Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-39Replacement . . . . . . . . . . . . . . . . . . . . . . 4-44Headstock Alignment . . . . . . . . . . . . . . . . . . 4-47Vertical. . . . . . . . . . . . . . . . . . . . . . . . . 4-47Horizontal . . . . . . . . . . . . . . . . . . . . . . . 4-48

Headstock Spindle . . . . . . . . . . . . . . . . . . . . . 4-50Spindle Lock Pin . . . . . . . . . . . . . . . . . . . . 4-50Lubrication . . . . . . . . . . . . . . . . . . . . . . . 4-50

Chapter 5 - ElectricalPower Case . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Accessing the Power Case . . . . . . . . . . . . . . . 5-1Component Description (HLV®-H Machine Power Case) . . 5-2Component Description (TFB®-H Machine Power Case) . . 5-4

Power Feed Control Panel . . . . . . . . . . . . . . . . . 5-6Power Feed Module . . . . . . . . . . . . . . . . . . 5-6Resistor Module . . . . . . . . . . . . . . . . . . . . 5-7Switches . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Variable Speed Control Panel. . . . . . . . . . . . . . . . 5-8Operator Controls. . . . . . . . . . . . . . . . . . . . 5-8

Spindle Speed Adjustment . . . . . . . . . . . . . . . . . 5-8Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Start/Stop Switch . . . . . . . . . . . . . . . . . . . . 5-8Spindle Brake (HLV-H Machines Only) . . . . . . . . . . 5-8Switch Replacement . . . . . . . . . . . . . . . . . . 5-9

Chapter 6 - MiscellaneousBed Levers (HLV-H Machines) . . . . . . . . . . . . . . . 6-1


Bed Levers (TFB-H Machines) . . . . . . . . . . . . . . . 6-12Removal . . . . . . . . . . . . . . . . . . . . . . . . 6-12Replacement . . . . . . . . . . . . . . . . . . . . . . 6-15

Coolant Facilities. . . . . . . . . . . . . . . . . . . . . . 6-18To Clean the Sump . . . . . . . . . . . . . . . . . . . 6-18Coolant Pump Motor Lubrication . . . . . . . . . . . . . 6-18

Tailstock . . . . . . . . . . . . . . . . . . . . . . . . . 6-19Tailstock Disassembly. . . . . . . . . . . . . . . . . . 6-19Tailstock Reassembly . . . . . . . . . . . . . . . . . . 6-23Tailstock Alignment . . . . . . . . . . . . . . . . . . . 6-25Horizontal . . . . . . . . . . . . . . . . . . . . . . . 6-26Vertical. . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Preventive Maintenance Schedule . . . . . . . . . . . . . 6-28Lubricant And Sealant Listing . . . . . . . . . . . . . . . . 6-29

INDEX

M-10C vii

- NOTES -

viii M-10C

CHAPTER 1 - CARRIAGE

CARRIAGE APRON DISASSEMBLY1. Press “Start/Stop” pushbutton “A”, Figure 1.1,

IN to turn the machine OFF.

2. Place a drain pan capable of holding onepint of liquid under drain plug “C”, Figure 1.2.

3. Remove and clean magnetic drain plug “C”.

4. Allow the reservoir to drain.

5. Replace magnetic drain plug “C”.

6. Remove the drain pan and properly disposeof the used oil.

7. Remove three screws “J” and remove powerfeed assembly “K”, Figure 1.3, from theapron cover.

8. Remove three screws “G” and removehandwheel assembly “D”.

9. Remove eight screws “L”, Figure 1.4, and clutch housings “M” and “N”.

- NOTE -Do not misplace the seal under cover “P”, Figure 1.5 .

10. Remove two screws “O” and cover “P”, Figure 1.5 .

M-10C 1-1

Figure 1.1 - Variable Speed Control Box(HLV®-H Machine Model Shown)

Tp4328.

Figure 1.2 - Magnetic Drain Plug

Tp4329.

Figure 1.3 - Carriage Handwheel andPower Feed Drive

Tp4330.

11. Remove taper pin “S”, Figure 1.6, to remove lead screw nut handle “U” and the fiberwasher under the lead screw nut handle

12. Remove lock screw “T”.

13. Remove seven screws “Q” from apron cover “R” .

- NOTE -The apron cover is sealed with Permatex® sealant.

14. Remove apron cover “R” :

a) Pull the cover outward with the left handwhile striking the edge of the cover with asoft-faced hammer until a crack appearsin the sealant. Refer to Figure 1.7 .

b) Tap the cover back into place.

c) Repeat steps “a” and “b” until the seal iscompletely broken and the apron covercan be removed.

15. Remove rack pinion and 70 tooth gear “V”,Figure 1.8 .

1-2 M-10C

Figure 1.4 - Carriage Clutch Housing

Tp4331.

Figure 1.5 - Carriage Cover

Tp4332.

Figure 1.6 - Lead Screw Nut Handle

Tp4333.

- WARNING -Spring “D”, Figure 1.9, is under tension. Use caution when loosening and re-moving nuts “A”.

- NOTE -Clutch components on the front side of the apron cover are identical, with the ex-ception of the springs. DO NOT interchange the springs.

16. Carefully loosen and remove two nuts “A”, Figure 1.9 .

17. Remove bearings “B”, washers “C”, springs “D”, spring seats “E”, and spacers “F”.

M-10C 1-3

Figure 1.7 - Apron Cover Removal

Tp4334.

Figure 1.8 - Apron Cover Assembly

Tp4335.

Figure 1.9 - Power Feed ClutchComponents

Tp4336.

Figure 1.10 - Clutch Removal

Tp4337.

18. Remove two nuts “G”, Figure 1.9, to removethe carriage and cross feed clutch assem-blies, as shown in Figure 1.10 .

- NOTE -It is not necessary to remove the snapring from bearing “K”, Figure 1.11, todisassemble the clutch assemblies.

19. Remove two clutch bearings “K”, Figure 1.11,from the face of the apron cover.

20. Remove intermediate gears “H”, Figure 1.10and “M”, Figure 1.12 .

21. If necessary, remove 70 tooth gear “I”, Fig-ure 1.11, by driving out stud “J”.

22. Remove screw “L”, Figure 1.11, to removeinterlock plate “N”, Figure 1.13 .

23. Remove longitudinal feed interlock bar “O”,Figures 1.13 and 1.14, and spring “P” andplunger “Q”, Figure 1.14 .

24. To disassemble the longitudinal (carriage)clutch assembly:

a) Remove snap ring “R”, Figure 1.15 .

b) Remove 70 tooth gear “S”, Figure 1.16 .

c) Remove clutch plate “T”.

d) Remove snap rings “U”, clutch disc “V”,clutch plate “W”, and wave washer “X”,Figure 1.17 .

1-4 M-10C

Figure 1.11 - Clutch Bearing Removal

Tp4338.

Figure 1.12 - Carriage Apron with CoverRemoved

Tp4339.

Figure 1.13 - Longitudinal Feed Interlock

Tp4340.

Figure 1.14 - Interlock Components

Tp4341.

M-10C 1-5

Figure 1.15 - Longitudinal (Carriage) Clutch

Tp4342.

Figure 1.16 - Longitudinal Clutch ComponentsTp4343.

Figure 1.17 - Longitudinal Clutch Components

Tp4344.

1-6 M-10C

Figure 1.18 - Cross Feed Clutch

Tp4345.

Figure 1.19 - Cross Feed Clutch Components

Tp4346.

Figure 1.20 - Cross Feed Clutch Components

Tp4347.

25. To disassemble the cross feed clutch assembly:

a) Remove snap ring “A”, Figure 1.18 .

b) Remove shaft and 70 tooth gear “B”, Figure 1.19 .

c) Remove clutch plate “C”.

d) Remove snap rings “D”, clutch disc “E”, clutch plate “F”, and wave washer “G”, Figure1.20 .

26. To disassemble the clutch housings:

a) Remove springs “H”, Figures 1.21 and 1.22, from the clutch housings.

b) Remove cap “K” and nut “L”, Figure 1.23, from each clutch housing.

c) Loosen set screw “P” and remove camshaft “N” from each clutch housing.

d) Remove sleeve “M” and bolt “O” from each clutch housing.

M-10C 1-7

Figure 1.21 - Longitudinal Clutch Plungerand Spring

Tp4348.

Figure 1.22 - Cross Feed Clutch Plungerand Spring

Tp4349.

Figure 1.23 - Clutch Housing and Components

Tp4350.

CARRIAGE APRON REASSEMBLY1. To reassemble the clutch housings:

a) Replace bolt “O” and sleeve “M”, Figure 1.23, in each clutch housing.

b) Replace camshaft “N” and tighten set screw “P” in each clutch housing.

c) Replace nut “L” and cap “K” in each clutch housing.

d) Replace interlock plunger “I”, Figure 1.21, and plunger “J”, Figure 1.22, in the clutchhousings.

e) Replace springs “H”, Figures 1.21 and 1.22, in the clutch housings.

2. To reassemble the longitudinal (carriage) clutch assembly:

a) Replace wave washer “X”, clutch plate “W”, clutch disc “V”, and snap rings “U”, Figure1.17 .

b) Replace clutch plate “T”, Figure 1.16 .

c) Replace 70 tooth gear “S”.

d) Replace snap ring “R”, Figure 1.15 .

3. To reassemble the cross feed clutch assembly:

a) Replace wave washer “G”, clutch plate “F”, clutch disc “E”, and snap rings “D”, Fig. 1.20.

b) Replace clutch plate “C”, Figure 1.19 .

c) Replace shaft and 70 tooth gear “B”.

d) Replace snap ring “A”, Figure 1.18 .

4. Install spring “P”, Figure 1.14, and plunger “Q” in longitudinal feed interlock bar “O”.

- NOTE -Longitudinal feed interlock bar “O”, Figure 1.13, must be positioned with the clear-ance chamfers as shown.

5. Replace longitudinal feed interlock bar “O”, as shown in Figure 1.13 .

6. Remount interlock plate “N”, Figure 1.13, using screw “L”, Figure 1.11 .

7. If removed, replace 70 tooth gear “I”, Figure 1.11 .

8. Replace intermediate gears “H”, Figure 1.10 and “M”, Figure 1.12 .

9. Replace clutch bearings “K”, Figure 1.11 .

10. Install the carriage and cross feed clutch assemblies in the apron cover as shown in Figure1.10, using two nuts “G”, Figure 1.9 .

11. Replace spacers “F”, spring seats “E”, springs “D”, washers “C”, and bearings “B”, Figure1.9 .

- NOTE -Compress springs “D”, Figure 1.9, until nuts “A” can be threaded on flush with thetop of the shaft. Note the bracket used in Figure 1.24 .

12. Install two nuts “A”, Figure 1.9 .

1-8 M-10C

13. Replace rack pinion and 70 tooth gear “V”,Figure 1.8 .

- CAUTION -Use care when installing the aproncover so as not to damage thegears.

14. Apply Permatex® sealant to apron cover “R”,Figure 1.6, and replace using seven screws“Q”.

15. Apply Permatex sealant to cover “P”, Figure1.5; then remount the cover seal and coverusing two screws “O”.

16. In the clutch housings, pack springs “H,~Figures 1.21 and 1.22, with Shell Alvania® #3grease.

17. Apply Permatex sealant to the surface ofclutch housings “M” and “N”, Figure 1.4, thatwill be against the carriage apron cover.

18. Remount clutch housings “M” and “N” using eight screws “L”.

19. Apply Permatex sealant to the surface of handwheel housing “H”, Figure 1.3, that will beagainst the carriage apron cover.

20. Remount handwheel assemblv “D” usinq three screws “G”.

21. Apply Permatex sealant to the surface of power feed housing “I”, that will be against thecarriage apron cover.

22. Remount power feed assembly “K” using three screws “J”.

23. Replace lock screw “T”, Figure 1.6 .

24. Replace the fiber washer, handle “U”, and taper pin “S”.

- NOTE -The carriage apron oil reservoir is full when sight window “E”, Figure 1.3, is com-pletely filled with oil.

25. Fill the carriage apron oil reservoir:

a) Remove cap “F”, Figure 1.3 .

b) Fill the carriage apron oil reservoir with Mobilfluid® 350 oil.

c) Replace cap “F”.

26. With the clutch handles in one of the notched positions (up or down), tighten screw “R”,Figure 1.25, in each clutch housing.

27. Adjust the clutches according to the instructions in the next section, “Clutch Adjustment”.

M-10C 1-9

Figure 1.24 - Clutch Spring Replacement

Tp4351.

CLUTCH ADJUSTMENT

- NOTE -When properly adjusted, each clutchwill release when the ball lever is be-tween 10° and 20° above horizontal.

1. Using a spanner wrench, remove threadedcover “K”, Figure 1.23, from each clutch as-sembly.

- NOTE -The clutches are spring loaded andcannot be adjusted for more pullingpower.

2. Adjust each clutch at nut “S”, Figure 1.25.

3. Replace threaded cover “K”, Figure 1.23, oneach clutch assembly.

CARRIAGE LOCK

REMOVAL

1. Press “Start/Stop” pushbutton “A”, Figure 1.1, IN to turn the machine OFF.

2. Place handle “U”, Figure 1.26, in the unlocked position.

3. Lift handle “U” UP to remove.

If it is necessary to remove the two piece lock bolt shown in Figure 1.27, proceed tostep 4.






9. Remove three screws “J” and remove powerfeed assembly “K”, Figure 1.3, from theapron cover.

10. Remove three screws “G” and removehandwheel assembly “D”.

11. Remove eight screws “L”, Figure 1.4, andclutch housings “M” and “N”.

1-10 M-10C

Figure 1.25 - Power Feed ClutchAdjustment

Figure 1.26 - Carriage Lock Handle

Tp4352.

Tp4353.

- NOTE -Do not misplace the seal under cover“P”, Figure 1.5 .

12. Remove two screws “O” and cover “P”, Fig-ure 1.5 .

13. Remove taper pin “S”, Figure 1.6, to removelead screw nut handle “U” and the fiberwasher under the lead screw nut handle


15. Remove seven screws “Q” from apron cover“R”.

- NOTE -The apron cover is sealed withPermatex® sealant.

16. Remove apron cover “R”:

a) Pull the cover outward with the left hand while striking the edge of the cover with asoft-faced hammer until a crack appears in the sealant. Refer to Figure 1.7 .


c) Repeat steps “a” and “b” until the seal is completely broken and the apron cover can beremoved.

17. Remove the two piece lock bolt, as shown in Figure 1.27 .

REPLACEMENT

1. If removed, replace the two piece lock bolt, as shown in Figure 1.27 .

2. Replace handle “U”, Figure 1.26 .

3. Check the carriage lock for proper operation.

4. Apply Permatex sealant to apron cover “R” and replace using seven screws “Q”, Figure1.6.

5. Apply Permatex sealant to cover “P”, Figure 1.5; then remount the cover seal and coverusing two screws “O”.

6. In the clutch housings, pack springs “H”, Figures 1.21 and 1.22, with Shell Alvania #3grease.

7. Apply Permatex sealant to the surface of clutch housings “M” and “N”, Figure 1.4, that willbe against the carriage apron cover.



10. Remount handwheel assembly “D” using three screws “G”.

11. Apply Permatex sealant to the surface of power feed housing “I” that will be against thecarriage apron cover.

M-10C 1-11

Figure 1.27 - Two Piece Lock Bolt

Tp4354.


13. Replace lock screw “T”, Figure 1.6 .







GEAR RACK

REMOVAL


- NOTE -Locking lever “V”, Figure 1.28, is shown in the locked position.

2. Release locking lever “V”, Figure 1.28, and remove the tailstock assembly from the end ofthe machine.

3. Remove the taper pin from positive stop “D”, Figure 1.29 .

1-12 M-10C

Figure 1.28 - Tailstock Locking Lever

Tp4355.

Figure 1.29 - Lead Screw and Bracket

Tp4356.

- NOTE -Taper pin “G”, Figure 1.30, connectsthe carriage lead screw to the gear boxcluster shaft.

4. Remove taper pin “G”, Figure 1.30 .

5. Engage carriage lead screw nut “I”, Figure1.31, with carriage lead screw “J” by rotatinglever “H” clockwise (as viewed from the frontof the machine).

6. Move the carriage approximately 1/2 inch toright using handwheel “D”, Figure 1.3 .

7. Disengage carriage lead screw nut “I”, Figure1.31, from carriage lead screw “J” by rotatinglever “H” counterclockwise.

8. Remove three bolts “K”, Figure 1.32 .

9. Set power feed control box “F”, Figure 1.29,toward the rear of the machine.

10. Move the carriage to the extreme left usinghandwheel “D”, Figure 1.3 .

11. Remove two screws “B”, Figure 1.29 .

M-10C 1-13

Figure 1.30 - Taper Pin for Lead Screw

Tp4357.

Figure 1.31 - Carriage Lead Screw Nut

Tp4358.

Figure 1.32 - Power Feed Control Box(End View)

Tp4359.

- CAUTION -Support lead screw “A” by hand while removing bracket “E” to prevent dam-age to the threads on the lead screw. Continue supporting lead screw “A”while it is being removed.

- NOTE -DO NOT lose any shims located between bracket “E” and the bed. These shimsare factory installed and must be present to ensure proper alignment of the bedand carriage ball screw “A”.

12. Remove bracket “E” and any shims located between the bracket and the bed:

a) Carefully pull bracket “E” straight away from the bed until the dowel pins in bracket “E”clear the bed.

b) Slide bracket “E” to the right to remove it from carriage lead screw “A” and stop rod “C”.

13. Remove carriage lead screw “J”, Figure 1.31, from the machine by carefully removing it tothe right through feed screw nut “I”.

14. Remove positive stop “D”, Figure 1.29 .

15. Move the carriage to the right using handwheel “D”, Figure 1.3, until travel stops.

16. Pull the carriage by hand past the end of thebed until gear rack “N”, Figure 1.33, is com-pletely exposed.

17. Remove eight screws “M”.

- NOTE -Dowel pins “L” may remain in the bedor come out with rack “N” when therack is removed.

18. Remove rack “N” by prying alternately andevenly at both ends of the rack with a smallscrewdriver to free the rack from the bed.

REPLACEMENT

- NOTE -Dowel pins “L”, Figure 1.33, may have remained in the bed or come out when rack“N” was removed.

1. Install rack “N”, Figure 1.33, on the bed:

a) Align dowel pins “L” with their mating holes.

b) Using a soft-faced hammer, tap rack “N” into position alternately and evenly.

2. Install and tighten eight screws “M”.

1-14 M-10C

Figure 1.33 - Carriage Rack

Tp4360.

3. Carefully pull the carriage toward the headstock until the carriage handwheel pinion en-gages carriage rack “N”.

4. Move the carriage to the extreme left using handwheel “D”, Figure 1.3 .

5. Install positive stop “D”, Figure 1.29, on stop rod “C”.

- CAUTION -Support lead screw “A” by hand while it is being installed to prevent damageto the threads on the lead screw. Continue supporting lead screw “A” whileinstalling bracket “E”.

- NOTE -The end of carriage lead screw closest to the headstock has a hole drilled thoughit to accept taper pin “G”, Figure 1.30 .

6. Install carriage lead screw “J”, Figure 1.31, in the machine by carefully moving it to the leftthrough feed screw nut “I”.

7. Install bracket “E”, Figure 1.29, and any shims that were located between the bracket andthe bed:

a) Slide bracket “E” to the left to install it on carriage lead screw “A” and stop rod “C”.

b) Align the dowel pins in bracket “E” with the dowel pin holes in the bed.

c) Position the shim(s) between bracket “E” and the bed.

d) Mount bracket “E” to the bed of the machine using two screws “B”.

8. Remount power feed control box “F”, Figure 1.29, using three bolts “K”, Figure 1.32 .

9. Move the carriage to the extreme right using handwheel “D”, Figure 1.3 .

10. Engage carriage lead screw nut “I”, Figure 1.31, with carriage lead screw “J” by rotating le-ver “H” clockwise.

11. Move the carriage approximately 1/2 inch to left using handwheel “D”, Figure 1.3 .

12. Disengage carriage lead screw nut “I”, Figure 1.31, from carriage lead screw “J” by rotatinglever “H” counterclockwise.

- NOTE -Properly align the tapered hole in the left end of carriage lead screw “J”, with thecorresponding hole in the gear box cluster shaft.

13. Install taper pin “G”, Figure 1.30 .

14. Install the taper pin in positive stop “D”, Figure 1.29 .

15. Replace the tailstock assembly on the machine.

LUBRICATION

Clean and lubricate the gear rack at least once a week:

1. Remove all chips and clean the gear rack using mineral spirts.

2. Lubricate the gear rack using a pressure oil can containing Mobil® Velocite® oil No. 6.

M-10C 1-15

GIB ADJUSTMENT

After a period of continued use, it may become necessary to adjust the carriage gib. The gib is thetapered type and adjustment is made from the large end of the gib at “O”, Figure 1.34 .

- NOTE -Excessive gib pressure or drag does not improve machine performance.

To adjust the carriage gib:

1. Insert a 1/4 inch hexagon wrench into adjusting screw “O”, Figures 1.34 and 1.35 .

2. Loosen adjusting screw “O” by turning the wrench one full turn in the counterclockwise di-rection.

3. Push the wrench through adjusting nut “O” and into adjusting nut “P”, Figure 1.35 .

4. Advance adjusting nut “P” by turning the wrench a fraction of a turn in the clockwise direc-tion.

- NOTE -Do not overtighten adjusting screw “O”.

5. Pull the wrench out of adjusting nut “P” and tighten adjusting nut “O” by turning the wrenchin the clockwise direction.

6. Test the carriage for “feel”. The carriage should have a slight drag, but it should not bind.

7. Repeat this procedure if necessary.

1-16 M-10C

Figure 1.34 - Carriage Gib Adjustment

Tp4361.

Figure 1.35 - Gib Adjustment Illustration

Adjusting Screw “P”

Adjusting Screw “O”

Tapered Gib - Large End

Ti1859.

¼” Hexagon Wrench

HANDWHEEL

After a period of continual use, it may become necessary to remove handwheel assembly “D”,Figure 1.3, to clean or replace internal components.

REMOVAL

1. Press “Start/Stop” pushbutton “A”, Figure 1.1,IN to turn the machine OFF.






7. Remove three screws “G”, Figure 1.3, andremove handwheel assembly “D”.

DISASSEMBLY

1. Remove the lock screw located at “S”, Figure1.36 .

2. Loosen the set screw located at “S”.

3. Remove handwheel “T”.

4. Remove key “U”, Figure 1.37 .

5. Remove shaft and 21 tooth gear “V”, Figures1.37 and 1.38 .

- NOTE -Do not misplace the nylon plug be-tween lock screw “B”, Figure 1.2, anddial “R”, Figure 1.36 .

6. Remove snap ring “X”, Figure 1.39, to re-move dial “Y”, from the handwheel.

M-10C 1-17

Figure 1.36 - Carriage HandwheelAssembly

Tp4362.

Figure 1.37 - Carriage HandwheelComponents

Tp4363.

REASSEMBLY

- NOTE -Be sure the nylon plug is in position before mounting dial “Y”, Figure 1.39, onto thehandwheel.

1. Mount dial “Y” onto the handwheel using snap ring “X”, Figure 1.39 .

2. Replace shaft and 21 tooth gear “V”, Figures 1.37 and 1.38 .

3. Replace key “U”, Figure 1.37 .

4. Replace handwheel “T”, Figure 1.36 .

5. Tighten the set screw located at “S”.

6. Install and tighten the lock screw located at “S”.

REPLACEMENT

1. Use Permatex® sealant on surface of hand-wheel housing “H”, Figure 1.3, that will beagainst carriage apron cover “R”, Figure 1.6 .

2. Replace handwheel assembly “D”, Figure1.3, using three screws “G”.

- NOTE -The carriage apron oil reservoir is fullwhen sight window “E”, is completelyfilled with oil.


a) Remove cap “F”.

b) Fill the carriage apron oil reservoir withMobilfluid® 350 oil.


1-18 M-10C

Figure 1.38 - Carriage Handwheel Components

Tp4364.

Figure 1.39 - Carriage Handwheel and Dial

Tp4365.

CLEARANCE ADJUSTMENT

- NOTE -The clearance between dial “R”, Figure 1.36, and zero ring “Q” should be set at.002" to .004" [.05mm to .1mm].

To adjust the clearance:

1. Loosen set screw “W”, Figure 1.38 .

2. Adjust the clearance between dial “R”, Figure 1.36, and zero ring “Q” as needed.

3. Tighten set screw “W”, Figure 1.38 .

LEAD SCREW(HLV®-H Machines only)

REMOVAL


- NOTE -Taper pin “G”, Figure 1.30, connects carriage ball screw “J”, Figure 1.31, to thegear box cluster shaft.


3. Engage carriage lead screw nut “I”, Figure 1.31, with carriage lead screw “J” by rotating le-ver “H” clockwise (as viewed from the front of the machine).

4. Move the carriage approximately ~2 inch to right using handwheel “D”, Figure 1.3 .



7. Set power feed control box “F”, Figure 1.29, toward the rear of the machine.



M-10C 1-19







- NOTE -Locating dowel pins “A”, Figure 1.40, and needle bearing “B” are press fit in leadscrew bracket “C”.

1-20 M-10C

Figure 1.40 - Lead Screw Bracket

Tp4366.

REPLACEMENT

- CAUTION -Support lead screw “A”, Figure 1.29, by hand while it is being installed toprevent damage to the threads on the lead screw. Continue supporting leadscrew “A” while installing bracket “E”.











6. Move the carriage approximately 1/2 inch to left using handwheel “D”, Figure 1.3 .


- NOTE -Properly align the tapered hole in the left end of carriage lead screw “J” with thecorresponding hole in the gear box cluster shaft.


LUBRICATION

Clean and lubricate the carriage lead screw at least once a week:

1. Remove all chips and clean the carriage lead screw using mineral spirits

2. Lubricate the carriage lead screw using a pressure oil can containing Mobil® Velocite® oilNo. 6.

M-10C 1-21

LEAD SCREW NUT(HLV®-H Machines only)

REMOVAL


- NOTE -Locking lever “V”, Figure 1.28, is shown in the locked position.

2. Release locking lever “V”, Figure 1.28, and remove the tailstock assembly from the end ofthe machine.

3. Remove the taper pin from positive stop “D”, Figure 1.29 .

- NOTE -Taper pin “G”, Figure 1.30, connects carriage ball screw “J”, Figure 1.31, to thegear box cluster shaft.



6. Move the carriage approximately 1/2 inch to right using handwheel “D”, Figure 1.3 .



9. Set power feed control box “F”, Figure 1.29, toward the rear of the machine.









4. Remove positive stop “D”, Figure 1.29 .

1-22 M-10C

15. Move the carriage to the right using handwheel “D”, Figure 1.3, until travel stops.

16. Pull the carriage to the right by hand until lead screw nut “D”, Figure 1.41, clears the bed.

17. Loosen two lock nuts “E”.

18. Loosen two screws “F”.

19. Remove two dot plugs “T”, Figure 1.25 .

- NOTE -Hold gib “G”, Figure 1.41, to prevent it from dropping from position.

20. Remove the two screws located under dot plugs “T”, Figure 1.25 .

21. Remove gib “G”, Figure 1.41 .

22. Remove lead screw nut “D”.

- NOTE -If it is necessary to remove gib “H” or cam “I”, Figure 1.42, perform steps 23through 37.

23. Place a drain pan capable of holding one pint of liquid under drain plug “C”, Figure 1.2 .




27. Remove the drain pan and properly dispose of the used oil.

28. Remove three screws “J”, Figure 1.3, and remove power feed assembly “K” from the aproncover.

29. Remove three screws “G” and remove handwheel assembly “D”.

30. Remove eight screws “L”, Figure 1.4, and clutch housings “M” and “N”.

M-10C 1-23

Figure 1.41 - Lead Screw Nut

Tp4367.

Figure 1.42 - Lead Screw Nut Removal

Tp4368.

- NOTE -Do not misplace the seal under cover“P”, Figure 1.5 .

31. Remove two screws “O” and cover “P”, Fig-ure 1.5 .

32. Remove taper pin “S”, Figure 1.6, to removelead screw nut handle “U” and the fiberwasher under the lead screw nut handle


34. Remove seven screws “Q” from apron cover“R”.

- NOTE -The apron cover is sealed withPermatex® sealant.

35. Remove apron cover “R” :

a) Pull the cover outward with the left handwhile striking the edge of the cover with asoft-faced hammer until a crack appearsin the sealant. Refer to Figure 1.7 .


c) Repeat steps “a” and “b” until the seal iscompletely broken and the apron covercan be removed.

36. Remove two screws “K”, Figure 1.43, and re-move gib “H”, Figure 1.42 .

37. Loosen screw “L”, Figure 1.43, and removecam “I”.

REPLACEMENT

1. Replace cam “I”, Figures 1.43 and 1.44, with cam slots “M”, Figure 1.44, in line with screw“L”, Figure 1.43 .

2. Replace gib “H”, Figure 1.42, using two screws “K”, Figure 1.43 .

- CAUTION -Use care when installing the apron cover so as not to damage the gears.

3. Apply Permatex sealant to apron cover “R”, Figure 1.6, and replace using seven screws”Q”.

4. Apply Permatex sealant to cover “P”, Figure 1.5; then, remount the cover seal and coverusing two screws “O”.

1-24 M-10C

Figure 1.43 - Lead Screw Nut Cam andGib Screws

Tp4369.

Figure 1.44 - Cam for Lead Screw Nut

Tp4370.

5. In the clutch housings, pack springs “H”, Figures 1.21 and 1.22, with Shell Alvania® #3grease.

6. Apply Permatex® sealant to the surface of clutch housings “M” and “N”, Figure 1.4, that willbe against the carriage apron cover.



9. Remount handwheel assembly “D” using three screws “G”.

10. Apply Permatex sealant to the surface of power feed housing “I” that will be against thecarriage apron cover.


12. Replace lock screw “T”, Figure 1.6, but do not tighten .







15. Replace both halves of lead screw nut “D”, Figure 1.41, placing the pins on the lead screwnut in cam slots “N”, Figure 1.44 .

16. Replace gib “G”, Figure 1.41 using the two screws removed in step 20 of the lead screwnut removal procedure.

17. Replace dot plugs “T”, Figure 1.25 .

18. Adjust the feed screw nut:

a) Tighten screw “L”, Figure 1.43, gradually clockwise until handle “U”, Figure 1.6, has ap-proximately 5 overtravel after lead screw nut pin “J”, Figure 1.42, contacts the upper halfof the lead screw nut.

b) Tighten lock screw “T”, Figure 1.6 .

c) Alternately tighten two screws “F”, Figure 1.41, until pressure is required to close thelead screw nut.

d) Tighten two lock nuts “E”.

19. Push the carriage toward the headstock slowly using care that the rack pinion and the rackengage properly.

20. Replace positive stop “D”. Figure 1.29 .

M-10C 1-25

- CAUTION -Support lead screw “A” by hand while it is being installed to prevent damageto the threads on the lead screw. Continue supporting lead screw “A” whileinstalling bracket"E".











26. Move the carriage approximately ~2 inch to left using handwheel “D”, Figure 1.3 .


- NOTE -Properly align the tapered hole in the left end of carriage lead screw “J” with thecorresponding hole in the gear box cluster shaft.


LUBRICATION

Clean and lubricate the lead screw nut at least once a week:

1. Remove all chips and clean the lead screw nut using mineral spirits

2. Lubricate the lead screw nut using a pressure oil can containing Mobil® Velocite® oil No. 6.

1-26 M-10C

CARRIAGE LUBRICATION SYSTEM

Lubricating oil for the carriage is channeled from lubricator “O”, Figure 1.45, to an oil junction blockat the rear of the carriage. From the junction box, the oil is fed through four tubes to channels in thetop and bottom of the carriage. Two of these channels can be seen when the cross slide is removed.On the bottom of the carriage is a large “X” shaped channel for lubricating the bed ways.

It is recommended that the metering unit on each oil feed tube assembly be replaced annually. Ifan oil tube assembly becomes plugged, the metering unit should be replaced.

- NOTE -If the machine is equipped with an Acu-Rite® III Digital Readout, it will be neces-sary to remove part of the digital readout system to gain access to junction blockcover “I”, Figure 1.53 .

REPLACING AN OIL FEED TUBE METERING UNIT


2. Remove the chip and coolant guard, if the machine is so equipped.

3. If the machine is equipped with an Acu-Rite III Digital Readout, perform steps 4 through41.

If the machine is not equipped with an Acu-Rite III digital readout, perform steps 15through 29.

4. Thoroughly clean the top of the carriage and cross slide using mineral spirits.

5. Remove two screws “S”, Figure 1.46, washers, lock washers, and clamp “R”.

6. Remove cover “T”.

7. Remove four screws “U”, Figure 1.47, and cover “V”.

8. Using cross slide handle “Q”, Figure 1.25, move the cross slide to align the threaded holesin read head “W”, Figure 1.48, with two access holes “X”.

M-10C 1-27

Figure 1.45 - Carriage Lubricator

Tp4371.

Figure 1.46 - Chip Cover and Clamp

Tp4372.

- NOTE -Brackets “C”, Figure 1.49, and the required screws are located in the machine doc-umentation package, located in a pocket inside the power case door.

9. Mount two brackets “C”, Figure 1.49, as follows:

a) Position the brackets over two access holes “X”, Figure 1.48 .

b) Install a long screw through the center hole in each bracket, but do not tighten.

c) Install a short screw through each of the four outer holes in each bracket, but do nottighten.

d) Tighten the center screws in the brackets; then the remaining four screws.

10. Remove four screws “A” and reader head cover “B”, Figure 1.49 .

11. Remove paper wire cover “D”, Figure 1.50 .

12. Remove screw “E”, Figure 1.51, to releasecable clamp “F”.

- CAUTION -Use extreme care when handlingreader head cable “J”, Figure 1.53 .Rough handling may result in dam-age to the reader head wiring.

13. Gently lift reader head cable connector “G”,Figure 1.52, and reposition reader head ca-ble “J”, Figure 1.53, as shown, to gain ac-cess to lubricator junction block cover “I”.

1-28 M-10C

Figure 1.47 - Scale and Reader HeadCovers

Tp4373.

Figure 1.48 - Mounting Holes forAlignment Brackets

Tp4374.

Figure 1.49 - Reader Head AlignmentBrackets

Tp4375.

- CAUTION -The reader head cable MUST be secured to eliminate the possibility of thecable moving. Damage to the reader head wires may result if the cable is al-lowed to move. Refer to Figure 1.53 .

14. Secure the reader head cable as shown in Figure 1.53 .

15. Remove four screws “H” and lubricator junction block cover “I”.

16. Remove four screws “K” and junction block “L”, Figure 1.54, to gain access to oil feed tubeassemblies “M”, “N”, “O”, and “P”, Figure 1.55 .

- NOTES -Oil feed tube assemblies “M” and “P”,Figure 1.55, feed oil to the channel inthe bottom of the carriage.

Oil feed tube assemblies “N” and “O”feed oil to the channels in the top ofthe carriage.

DO NOT interchange the oil feed tubeassemblies. To avoid interchanging theoil feed tube assemblies, it is recom-mended that they be serviced one at atime.

17. Remove the oil feed tube assembly from thecarriage.

18. Remove oil tube “U”, Figure 1.56, from thefeed tube assembly by unthreading nut “T”.

M-10C 1-29

Figure 1.50 - Reader Head Wire Cover

Tp4376.

Figure 1.51 - Reader Head Cable Clamp

Tp4377.

Figure 1.52 - Reader Head CableConnector

Tp4378.

19. Using a 7/16 inch wrench, remove metering unit “S” from connector “R”.

- CAUTION -When installing a new metering unit in connector “R”, be sure not toovertighten the metering unit.

20. Using a 7/16 inch wrench, install the new metering unit in connector “R”.

- NOTE -When installing an oil feed tube, be sure the non-tapered end of the oil feed tube isinserted into the metering unit.

1-30 M-10C

Figure 1.53 - Reader Head Cable Secured

Tp4379.

Figure 1.54 - Lubricator Junction Box

Tp4380.

21. Install oil tube “U” on the feed tube assembly.

22. Tighten nut “T”.

23. Check O-ring “Q” for possible replacement.

- NOTES -When installing an oil feed tube assembly, be sure the tapered end of the oil feedtube is seated properly in the bushing located inside the carriage.

One method that may be used to check if an oil feed tube is seated properly is tocheck the alignment of the connector on the oil feed tube assembly in questionwith the connectors on the other three oil feed tube assemblies.

24. Install the oil feed tube assembly in the carriage.

- NOTE -A seating tool similar to tool “V” can easily be manufactured from aluminum orbrass. The diameter of the pin shown on the right end of tool “V” must be smallenough to fit inside the hole in the oil feed tube assembly.

25. Gently seat the oil feed tube by placing the seating tool against the oil feed tube assembly,as shown in Figure 1.57, and gently tapping the seating tool with a hammer.

26. Repeat steps 17 through 25, as needed, for the other oil feed tube assemblies.

27. Remount lubricator junction block “L” using four screws “K”, Figure 1.54 .

28. Install cover “I” using four screws “H”, Figure 1.53 .

29. Refill carriage lubricator “O”, Figure 1.45, with Mobil® Vactra® oil No. 2.

- CAUTION -

Use extreme care when handling reader head cable “J”, Figure 1.53 . Roughhandling may result in damage to the reader head wiring.

M-10C 1-31

Figure 1.55 - Oil Feed Tube Assemblies in the Carriage

Tp4381.

30. Hold cable “J”, Figure 1.53, while releasing it

31. Gently reposition cable connector “G”, Figure 1.52 .

32. Remount cable clamp “F”, Figure 1.51, using mounting screw, but do not tighten fully.

33. Remove any slack in cable “J”, Figure 1.53, between cable connector “G”, Figure 1.52, andcable clamp “F”, Figure 1.51 .

34. Tighten clamp mounting screw “E”, Figure 1.51 .

35. Replace paper wire cover “D”, Figure 1.50 .

36. Replace reader head cover “B”, Figure 1.49, using four screws “A”.

37. Remove two brackets “C” as follows:

a) Remove the two outside screws from each bracket.

b) Remove the screw from the center of each bracket.

1-32 M-10C

Figure 1.56 - Oil Feed Tube Assembly

Tp4382.

Figure 1.57 - Oil Feed Tube Assembly Installation

Tp4383.

- WARNING -Be sure to follow the procedure outlined in the operator’s manual for safelyaccessing the power case.

38. Place the two brackets and the six screws removed in step 37 in the machine documenta-tion package, located in a pocket inside the power case door.

39. Mount cover “V”, Figure 1.47, using four screws “U”.

40. Replace cover “T”, Figure 1.46 .

41. Replace clamp “R”, washers, lock washers, and two screws “S”.

OPERATING THE LUBRICATOR

To operate the lubricator, lift the plunger on lubricator “O”, Figure 1.45, hold the plunger up briefly,and release. DO NOT PUSH THE PLUNGER DOWN. Allow the plunger to return to the downposition on it’s own.

Operate the lubricator as often as required to keep the bed ways wet or a minimum of once a day.

FILLING THE LUBRICATOR RESERVOIR

To fill the oil reservoir, open reservoir cap “P”, Figure 1.45, and fill with Mobil® Vactra® oil No. 2.Maintain the oil level in sight gauge “Q”, Figure 1.46 .

M-10C 1-33

- NOTES -

1-34 M-10C

CHAPTER 2 - CROSS SLIDE AND TOOL POST

CROSS SLIDE FEED SCREW

DISASSEMBLY

1. Loosen nut “C”, Figure 2.1 .

2. Remove lock screw “A”.

3. Loosen the set screw located under lockscrew “A”.

4. Remove handle “B”.

5. Remove nut “C”.

- NOTE -Do not misplace the nylon plug locatedunder the lock screw in washer andscrew assembly “D”.

6. Remove washers and screw assembly “D”.

7. Remove dial “F”, and bushing “G”, Figure2.2.

8. Remove two screws “H”,Figure 2.3 .

9. Remove cross feed screw and end cap assembly, as shown in Figure 2.4 .

10. Remove nut “I”, two bearings “J”, and feed screw “M” from end cap “K”, Figure 2.5 .

M-10C 2-1

Figure 2.1 - Cross Slide Feed ScrewHandle and Dial

Tp4384.

Figure 2.2 - Dial and Bushing

Tp4385.

Figure 2.3 - End Cap and Zero Ring

Tp4386.

REASSEMBLY

1. Assemble feed screw “M”, two bearings “J”,nut “I”, and end cap “K”, Figure 2.5 .

2. Lubricate the cross feed screw with Mobil®Vactra® Oil No. 6.

3. Replace the cross feed screw and end capassembly, as shown in Figure 2.4 .

4. Replace two screws “H”, Figure 2.3 .

5. Replace bushing “G”, Figure 2.2, and dial“F”, Figures 2.1 and 2.2 .

- NOTE -When replacing washer and screw as-sembly “D”, Figure 2.1, be sure the ny-lon plug is in position under the lockscrew.

6. Replace washer and screw assembly “D”, Figure 2.1 .

7. Replace nut “C”.

8. Replace handle “B”.

9. Tighten the set screw and replace lock screw “A”.

10. Tighten nut “C”.

2-2 M-10C

Figure 2.4 - Cross Slide Feed Screw Removal

Figure 2.5 - Cross Slide Feed Screw andComponents

Tp4388.

Tp4387.

- NOTE -The gap between zero ring “E” and dial “F”, Figure 2.1, should be set at 0.002”[0.05mm] to 0.004” [0.1mm].

11. Check the gap between zero ring “E” and dial “F”, Figure 2.1 . If the gap needs to be ad-justed, proceed to step 11. If the gap is correct, this procedure is complete.

12. Loosen set screw “L”, Figure 2.5 .

13. Adjust the gap between zero ring “E” and dial “F”, Figure 2.1 .

14. Tighten set screw “L”, Figure 2.5 .

15. Repeat step 10.

CROSS SLIDE FEED SCREW NUT ADJUSTMENT1. Remove screw “N”, Figure 2.6 .

2. Remove cover “O”.

3. Loosen screw “P”, Figure 2.7 .

4. Turn adjusting screw “Q” gradually clockwise to reduce the feed screw backlash to a maxi-mum of four graduations on the cross feed dial.

5. Tighten screw “P”.

6. Replace cover “O”, Figure 2.6, in the center of the slot with the long end of the cover to-ward the rear of the machine.

7. Replace screw “N”.

M-10C 2-3

Figure 2.6 - Cover for Cross Slide FeedScrew Nut

Tp4389.

Figure 2.7 - Nut for Cross Slide FeedScrew

Tp4390.

CROSS SLIDEThe cross slide should be removed monthly to clean and lubricate the cross feed screw and nut

and to clean the cross slide ways. Lubricate the cross slide feed screw and feed screw nut withMobil® Vactra® Oil No. 2.

REMOVAL

1. Remove the tooling and the tool post.

2. Loosen and remove eccentric lock “R”, Figure 2.8 .

3. Lift the tool post slide from the cross slide.

4. Rotate cross slide handle “B”, Figure 2.1, clockwise to feed the cross slide toward the rearof the machine until travel stops.

5. Remove the chip and coolant shield, if themachine is so equipped.

6. Remove the cross slide from the rear of themachine by hand, as shown in Figure 2.9.

7. Clean the cross slide ways with mineral spir-its.

REPLACEMENT

1. Lubricate the cross slide ways with MobilVactra Oil No. 2.

2. Lubricate the feed screw nut with MobilVactra Oil No. 2.

- CAUTIONDuring cross slide replacement, donot force the cross slide into posi-tion. Damage to the feed screw orfeed screw nut may result.

3. Start the cross slide onto the carriage dove-tail and move it slowly into position whileturning cross slide handle “B”, Figure 2.1,counterclockwise until the feed screw en-gages the feed screw nut.

4. If three cross slide wipers “V”, Figure 2.10,have been disturbed, adjust the clearancebetween the wipers and the dovetail sur-faces:

a) Loosen screws “W”.

b) Set the clearance between the wipers andthe dovetail surfaces at .001" [.025mm].

c) Tighten screws “W”.

2-4 M-10C

Figure 2.8 - Tool Post Assembly

Tp4391.

Figure 2.9 - Cross Slide Removal

Tp4392.

- NOTE -

The cross slide should be positionedover the slot in the carriage dovetailbefore mounting the tool post slide.

5. Replace the tool post slide on the crossslide.

6. Replace and tighten eccentric lock “R” Figure2.8 .

7. Remount the chip and coolant shield.

CROSS SLIDE GIB ADJUSTMENT

After considerable use, it may be necessary to adjust the cross slide gib.

1. Insert 1/4" hex wrench into screw “X”, Figures 2.10 and 2.11, and loosen one full turn.

- NOTE -

Excessive gib pressure or drag does not improve machine performance.

2. Insert 1/4" hex wrench through screw “X” and into screw “Y”, Figure 2.11 .

3. Advance screw “Y” a fraction of a turn to increase gib pressure or retract screw “Y” a frac-tion of a turn to decrease gib pressure.

- CAUTION -

Do not overtighten screw “X”.

4. Pull the hex wrench out of screw “Y” andtighten screw “X” until snug.

- NOTE -

The cross slide should have a slightdrag, but should not bind.

5. Move the cross slide to test for proper gibadjustment:

If the gib is not properly adjusted, repeat thisprocedure.

If the gib is properly adjusted this procedureis complete.

M-10C 2-5Revised: June 26, 2007

Figure 2.10 - Cross Slide Wipers and GibAdjustment


Adjusting Screw “Y”

Adjusting Screw “X”


Ti1859.


TOOL POST

TOOL POST SLIDE DISASSEMBLY


2. Loosen and remove eccentric lock “R”, Fig-ure 2.8 .


4. Remove four screws “Z”, Figure 2.12 .

5. Turn handle “B”, Figure 2.1, counterclock-wise to remove the end cap and dial assem-bly from the slides, as shown in Figure 2.13 .

6. Disassemble end cap and dial assembly:

a) Loosen nut “C”, Figure 2.14 .

b) Remove lock screw “A”.

c) Loosen the set screw located under lockscrew “A”.

d) Remove handle “B”.

e) Remove nut “C”.

- NOTE -Do not misplace the nylon plug located under the lock screw in washer and screwassembly “D”, Figure 2.15 .

f) Remove washer and screw assembly “D”, Figure 2.15 .

g) Remove dial “E” and bushing “F”.

h) Remove two plugs “G” and springs “H”.

i) Remove nut “I”.

j) Remove feed screw “J” and two bearings “K”, Figure 2.16 .

k) Remove screw “L”, wave washer “M”, and handle “N”, Figure 2.17 .

l) Remove two screws “O”, eccentric support “P”, and eccentric shaft “Q”, Figure 2.18 .

m) Loosen nut “R” and remove eccentric stop “S”, Figure 2.19 .

n) Remove end cap “T” from housing “U”, Figure 2.20 .

o) Remove block “V”.

2-6 M-10C

Figure 2.12 - Tool Post Slide

Tp4394.

7. Disassemble the slides and feed screw nut:

a) Separate the slides by moving the top slide to the rear.

b) Loosen lock nut “W”, Figure 2.21 .

c) Unscrew half nut “X”.

d) Loosen set screw “A”, Figure 2.22, and remove half nut “Y”, Figure 2.21 .

- NOTE -Screw “B”, Figure 2.22, and screw “C”, Figure 2.23, are stop screws. It is not nec-essary to disturb these screws during disassembly.

M-10C 2-7

Figure 2.13 - End Cap and Dial AssemblyRemoval

Tp4395.

Figure 2.14 - End Cap and Dial Assembly

Tp4396.

Figure 2.15 - End Cap and Dial Components

Tp4397.

TOOL POST SLIDE REASSEMBLY

- CAUTION -Do Not overtighten set screw “A”,Figure 2.22 . Distortion of half nut“Y”, Figure 2.21, may result.

- NOTE -The counterbored hole in half nut “Y”,Figure 2.21, must be lined up with setscrew “A”, Figure 2.22 .

1. Reassemble the slides and feed screw nut:

a) Replace feed screw half nut “Y”, Figure2.21, and tighten set screw “A”, Figure 2.22.

- NOTE -After replacing half nut “X”, Figure2.21, do not tighten lock nut “W” untilinstructed.

b) Thread half nut “X”, Figure 2.21, into thecasting, leaving approximately 11/32 inch[8.7mm] projecting from the casting.

c) Coat the inside of the feed screw nut withDie Makers Grease.

d) Assemble the top and bottom slides.

2-8 M-10C

Figure 2.16 - End Cap and Feed Screw

Tp4398.

Figure 2.17 - Handle Removal

Tp4399.

Figure 2.18 - Eccentric for Handle

Tp4400.

Figure 2.19 - Stop Screw for Handle

Tp4401.

2. Reassemble the end cap and dial assembly:

- NOTE -The hole in block “V” is located off center and should be positioned left of center,as viewed in Figure 2.20 .

a) Coat block “V”, Figure 2.20, with Die Makers Grease and replace as shown.

b) Assemble end cap “T” and bearing housing “U”.

- NOTE -After replacing eccentric stop screw “S”, Figure 2.19, do not tighten lock nut “R”until instructed.

c) Replace eccentric stop screw “S”, Figure 2.19 .

d) Coat the eccentric end of shaft “Q”, Figure2.18, with Die Makers Grease; then re-place shaft “Q” as shown.

e) Replace eccentric support “P” and twoscrews “O”.

f) Replace handle “N”, wave washer “M”,and screw “L”, Figure 2.17 .

g) Replace bearings “K” and feed screw “J”,Figure 2.16, in the end cap.

h) Replace nut “I”, Figure 2.15 .

i) Replace two springs “H” and plugs “G”.

j) Replace bushing “F” and dial “E”.

- NOTE -When replacing washer and screw as-sembly “D”, be sure the nylon plug isin position under the lock screw.

k) Replace washer and screw assembly “D”.

l) Replace nut “C”.

m) Replace handle “B”, Figure 2.14 .

n) Tighten the set screw located at “A”.

o) Install and tighten the lock screw locatedat “A”.

p) Tighten nut “C”.

3. Coat the feed screw with Mobil® Vactra® OilNo. 2.

M-10C 2-9

Figure 2.20 - End Cap and BearingHousing

Tp4402.

Figure 2.21 - Adjustable Feed Screw Nut

Tp4403.

- CAUTION -DO NOT force the feed screw into the feed screw nut. Turn half nut “E”, Fig-ure 2.24, gradually until it lines up with half nut “Y”, Figure 2.21, to permit as-sembly of the tool post slide assembly.

4. Replace the end cap and dial assembly using four screws “Z”, Figure 2.12 .

- NOTE -The gap between dial “E”, Figure 2.15, and zero ring “I”, Figure 2.24, should be setat .002" [.05mm] to .004" [.1mm].

5. Check the gap between dial “E”, Figure 2.15,and zero ring “I”, Figure 2.24 .

If the gap needs to be adjusted, proceed tostep 6.

If the gap is correct, proceed to step 10.

6. Loosen set screw “H”, Figure 2.24 .

7. Adjust the gap between dial “E”, Figure 2.15,and zero ring “I”, Figure 2.24 .

8. Tighten set screw “H”, Figure 2.24 .

9. Repeat step 5.

2-10 M-10C

Figure 2.22 - Stop Screw and Half NutRetaining Screw

Tp4404.

Figure 2.23 - Stop Screw for Top Side

Tp4405.

Figure 2.24 - End Cap and Dial

Tp4406.

- NOTE -The clearance between wiper “T”, Figure 2.8, and the bottom slide should be set at.0015" [.038mm].

10. Check the clearance between wiper “T”, Figure 2.8, and the bottom slide.

If the clearance needs to be adjusted, proceed to step 11.

If the clearance is correct, proceed to step 13.

11. Loosen two screws “U” and adjust the clearance.

12. Tighten two screws “U”.

13. Turn the tool post slide assembly over to have the bottom slide facing upward.

14. Turn feed screw handle “B”, Figure 2.14, to separate the top and bottom slides and to ex-pose lock nut “D”, Figure 2.24, and adjustable feed screw half nut “E”.

- NOTE -Maximum allowable backlash is two graduations on the tool post feed screw dial.

15. Adjust half nut “E” IN for minimum backlash.

16. Hold half nut “E” and tighten lock nut “D”.

17. Replace the tool post slide assembly on the cross slide.

18. Replace eccentric lock “R”, Figure 2.8 .

19. Turn eccentric stop screw “F”, Figure 2.24, until it bottoms out; then back it off two fullturns.

- NOTE -To get positive holding and repeatability, adjust eccentric screw “F” to obtain equalthrow of lever “J” in both directions from the point perpendicular with the crossslide feed screw.

20. If necessary, adjust eccentric screw “F” to obtain the proper range of movement for lever“J”.

- NOTE -Fine adjustments to eccentric screw “F” from this point may be necessary to obtainthe desired solid stop.

21. Hold eccentric screw “F” with a hex wrench and tighten lock nut “G”.

M-10C 2-11

TOOL POST SLIDE FEED SCREW NUT ADJUSTMENT

Following considerable use or after disassembly of the tool post slide, it may be necessary toadjust the feed screw nut for proper backlash.




4. With the bottom slide UP, rotate feed screw handle “B”, Figure 2.14, to separate the topand bottom slide and to expose adjustable feed screw nut “E”, Figure 2.24 .

5. Loosen lock nut “D”.

6. Adjust half nut “E” IN for minimum backlash.

7. Hold half nut “E” and tighten lock nut “D”.



TOOL POST SLIDE LUBRICATION

The tool post slide should be removed monthly to lubricate the feed screw and nut, and to cleanand lubricate the slide ways. Use Mobil® Vactra® Oil No. 2 to lubricate the feed screw, feed screw nut,and slide ways.




4. Lubricate the feed screw and feed screw nut “E”, Figure 2.24 .

5. Clean and lubricate the slide ways



2-12 M-10C

TOOL POST SLIDE GIB ADJUSTMENT

After considerable use, it may be necessary to adjust the tool post slide gib.

1. Insert 1/4" hex wrench into screw “S”, Figures 2.8 and 2.25, and loosen one full turn.

- NOTE -Excessive gib pressure or drag does not improve machine performance.

2. Insert 1/4" hex wrench through screw “S” and into screw “K”, Figure 2.25 .

3. Advance screw “K" a fraction of a turn to increase gib pressure or retract screw “K” a frac-tion of a turn to decrease gib pressure.

- CAUTION -Do not overtighten screw"S".

4. Pull the hex wrench out of screw “K” and tighten screw “S” until snug.

- NOTE -The tool post slide should have a slight drag, but should not bind.

5. Move the tool post slide to test for proper gib adjustment:

a) If the gib is properly adjusted this procedure is complete.

b) If the gib is not properly adjusted, repeat this procedure.

M-10C 2-13


Adjusting Screw “P”

Adjusting Screw “O”


Ti1859.


- NOTES -

2-14 M-10C

CHAPTER 3 - SPINDLE AND POWER FEED DRIVES

SPINDLE DRIVE

CHECKING DRIVE BELT TENSION

- NOTE -If the drive belts slip when they are properly adjusted, the machine is being over-loaded.

1. On HLV®-H machines, place lever “A”, Figure 3.1, in the “Stop” position and lever “B” in thecenter position.

On TFB®-H machines, place lever “F”, Figure 3.2, in the “Brake” position and lever “G” inthe “Stop” position.

2. Pull “Start/Stop” pushbutton “D”, Figure 3.1, OUT to turn the machine ON.

3. On HLV-H machines, turn brake switch “E” to the OFF position.

4. On HLV-H machines, place lever “A” in “High” range.

On TFB-H machines, place lever “F”, Figure 3.2, in “Forward” or “Reverse” and lever “G” in“High” range.

5. Turn speed adjustment knob “C”, Figure 3.1, to “Faster” and hold in that position until spin-dle speed stabilizes at 3000 rpm.

M-10C 3-1

Figure 3.1 - HLV-H Headstock Figure 3.2 - TFB-H Headstock

Tp4407. Tp4408.

6. On HLV®-H machines, place lever “A” in the“Stop” position and allow the spindle to coastto a stop.

On TFB®-H machines, place lever “G”, Fig-ure 3.2, in the “Stop” position and allow thespindle to coast to a stop.

7. Press “Start/Stop” pushbutton “D”, Figure3.1, IN to turn the machine OFF.

8. Open door “H”, Figure 3.3.

- NOTE -The drive belts should not be loose orexcessively tight. Proper belt tensionwill allow approximately 3/4 inch [19.1mm] of belt deflection per side byhand.

9. Check drive belts “I” and “N”, Figure 3.4, forproper tension.

If the drive belts are not properly adjusted,refer to the next section, “Adjusting DriveBelt Tension”.

ADJUSTING DRIVE BELT TENSION



3. Determine whether the drive belts are tooloose or too tight.

4. Loosen lock nut “P”, Figure 3.5.

5. Turn adjusting screw “Q”:

Clockwise to lower the drive motor andtighten the drive belts.

Counterclockwise to raise the drive motorand loosen the drive belts.

6. Tighten lock nut “P”.

7. Recheck drive belt tension. Refer to the pre-vious section, “Checking Drive Belt Tension”.

8. Close door “H”, Figure 3.3.

3-2 M-10C

Figure 3.3 - Pedestal Door

Tp4409.

Figure 3.4 - Spindle Drive Compartment

Tp4410.

MOTOR AND SPINDLE BELT REPLACEMENT

1. On HLV®-H machines, place lever “A”, Figure3.1, in the “Stop” position and lever “B” in thecenter position.

On TFB®-H machines, place lever “F”, Figure3.2, in the “Brake” position and lever “G” inthe “Stop” position.

2. Pull “Start/Stop” pushbutton “D”, Figure 3.1,OUT to turn the machine ON.

3. On HLV-H machines, place lever “A”, Figure3.1, in “Low” range.

On TFB-H machines, place lever “F”, Figure3.2, in “Forward” or “Reverse” and lever “G”in “Low” range.

4. Turn speed adjustment knob “C”, Figure 3.1,to “Slower” and hold in that position untilspindle speed stabilizes at 125 rpm.

5. On HLV-H machines, place lever “A” in the“Stop” position to stop the spindle

On TFB-H machines, place lever “F”, Figure3.2, in the “Brake” position and lever “G” inthe “Stop” position.


7. Open door “H”, Figure 3.3 .

8. Remove lock nut “P”, Figure 3.5.

9. Raise the front of the motor mounting plateapproximately two inches and block it in thisposition, as shown in Figure 3.6.

10. Roll motor belt “S”, Figure 3.7, to the right offthe pulley and let it rest on the pulley hub, asshown.

11. Loosen mounting bolts “U” on brake assem-bly “X”, Figure 3.8 .

12. Pull the brake assembly away from motor pulley “T”.

13. Remove the motor belt from motor pulley “T”.


- WARNING -Stay clear of the spindle drive motor compartment while the spindle motor isrunning.

M-10C 3-3

Figure 3.5 - Drive Belt Adjusting Screw

Tp4411.

Figure 3.6 - Motor Mounting Plate Blockedin Position

Tp4412.

15. On HLV®-H machines, place lever “A” in“High” range.

On TFB®-H machines, place lever “F”, Figure3.2, in “Forward” or “Reverse” and lever “G”in “High” range.

16. Turn speed adjustment knob “C”, Figure 3.1,to “Faster” and hold in that position until pul-ley hanger assembly “Y”, Figure 3.9, reachesmaximum upward travel.

17. On HLV-H machines, place lever “A”, Figure3.1, in the “Stop” position and allow the spin-dle motor to coast to a stop.

On TFB-H machines, place lever “G”, Figure3.2, in the “Stop” position and allow the spin-dle motor to coast to a stop.


19. Slide countershaft assembly “Z”, Figure 3.9, to the extreme right and remove both beltsover the left end of the countershaft.

20. Remove the cotter pin from the end of speed change pull rod “A”, Figure 3.10, whichpasses through the headstock belt in the motor compartment.

21. Move the headstock belt around the end of the pull rod.

22. Remove the collet closer according to the procedure outlined Chapter 4.

23. Remove snap ring “B”, Figure 3.11, and handwheel “C”.

24. Remove key “D”, Figure 3.12, and washers “E” and “F”.

3-4 M-10C

Figure 3.7 - Motor Belt on Pulley Hub

Tp4413.

Figure 3.8 - Spindle Brake

Tp4414.

Figure 3.9 Belt Removal Over Countershaft

Tp4415.

- On HLV®-H machines, proceed to step 27.

- On TFB®-H machines, proceed to step 25.

25. Remove four screws “I” and cover “J”, Figure 3.13.

26. Proceed to step 34.

27. Remove covers “K” and “L”, Figure 3.14.

M-10C 3-5

Figure 3.10 - Speed Change Pullrod

Tp4416.

Figure 3.11 - Spindle Handwheel

Tp4417.

Figure 3.12 - Handwheel Washers and Key

Tp4418.

Figure 3.13 - Headstock Cover(TFB-H Machines)

Tp4419.

28. Remove snap ring “G”, Figure 3.12.

29. Turn push screw “H”, Figure 3.12 clockwiseto remove the gear, shaft, and bearing, asshown in Figure 3.15.

30. Remove lock screw “M, Figure 3.16.

31. Remove lock screw “N” and loosen the setscrew under lock screw “N”.

32. Unscrew shaft “O”, Figure 3.17, with a hexwrench.

33. Pull shaft “O” out approximately 5 inches[127mm].

- NOTE -Pull the spindle drive belt part way outof the top opening in the rear of thegear box (refer to Figure 3.17, to aid inthe passing the narrow width of thespindle belt past the underside of thespindle pulley and over the boss in thegear box housing.

34. Use a piece of wire as a hook to lift the spindle belt out of the pulley and out of the open-ing in the headstock.

35. Slide the new motor belt over the left end of countershaft assembly “Z”, Figure 3.9, andonto the right pulley on the countershaft assembly.

36. Cross the new spindle belt, as shown in Figure 3.18, feed it into the headstock and downinto the pedestal.

37. Use a piece of wire as a hook to lift the spindle belt into the spindle pulley.

38. Move the headstock belt over the end of pull rod “A”, Figure 3.10.

3-6 M-10C

Figure 3.14 - Gear Box Covers

Tp4420.

Figure 3.15 - Idler Gear and Shaft Removal

Tp4421.

39. Slide the new headstock belt over the left end of countershaft assembly “Z”, Figure 3.9,and onto the left pulley of the countershaft assembly.

40. Remount the countershaft assembly by sliding the left end of the countershaft assemblyback into countershaft support bracket “Y”.

41. Reconnect pull rod “A”, Figure 3.10, and insert the cotter pin removed in step 20.

- On HLV®-H machines, proceed to step 42.

- On TFB®-H machines, proceed to step 49.

42. Replace shaft “O”, Figure 3.17.

43. Replace lock screw “M”, Figure 3.16.

44. Replace the set screw and lock screw “N”.

- NOTE -Match timing mark “K”, Figure 3.19, on theworm gear and timing mark “L” on the pin-ion.

45. Back off push screw “H”, Figure 3.12,counterclockwise to replace the gear, shaft,and bearing, as shown in Figure 3.15 .

46. Replace snap ring “G”, Figure 3.12.

47. Replace covers “K” and “L”, Figure 3.14.


M-10C 3-7

Figure 3.16 - Gear Box Shifter Fork

Tp4422.

Figure 3.17 - Spindle Belt Removal

Tp4423.

Figure 3.18 - Spindle Belt Replacement

Tp4424.

49. Replace cover “J” and four screws “I”, Figure 3.13.

50. Replace washers “F” and “E”, Figure 3.12,and key “D”.

51. Replace handwheel “C”, Figure 3.11,and snap ring “B”.

52. Remount the collet closer according to the procedure outlined in Chapter 4.

53. Pull “Start/Stop” pushbutton “D”, Figure 3.1,OUT to turn the machine ON.


54. On HLV®-H machines, place lever “A” in “Low” range

On TFB®-H machines, place lever “G”, Figure 3.2, in “Low” range and lever “F” in “For-ward” or “Reverse”.

55. Turn speed adjustment knob “C”, Figure 3.1, to “Slower” and hold in that position until pul-ley hanger assembly “Y”, Figure 3.9, reaches maximum downward travel.

56. On HLV-H machines, place lever “A”, Figure 3.1, in the “Stop” position and allow the spin-dle motor to coast to a stop.

On TFB-H machines, place lever “F”, Figure 3.2, in the “Brake” position and lever “G” inthe “Stop” position.

- WARNINGS -The spindle brake is not in position to stop the spindle. Allow the spindle tocome to a complete stop.

Be sure the machine is turned OFF before attempting to work in the motorcompartment.

57. Press “Start/Stop” pushbutton “D”, Figure3.1,N to turn the machine OFF.

58. Install the motor belt on motor pulley “T”, Fig-ure 3.8 .

59. Realign spindle brake “X” with the brakingsurface on the motor pulley and tighten twobrake mounting bolts “U”.

60. Check and adjust the gap between the corkinsert in the brake and the braking surfaceon the spindle motor pulley. Refer to “SpindleBrake Gap Adjustment”, Page 3-10.

61. Remove the block and carefully lower thefront of the motor mounting plate.

62. Install lock nut “P”, Figure 3.5, but do nottighten.

3-8 M-10C

Figure 3.19 - Timing Marks for Worm Gearand Pinion

Tp4425.

63. Adjust belt tension according to the procedure outlined in “Adjusting Drive Belt Tension”,Page 3-2.

64. Turn stop collar “J”, Figure 3.4, down on the trip rod 1 inch [25.4mm] from the top of therod.

65. Adjust stop collar “J” gradually upward, running the speed change mechanism betweensettings, until the spindle belt is flush to 1/16 inch [1.6mm] out of the countershaft pulleywhen the limit switch stops upward motion.

66. Tighten the set screw in stop collar “J”.

67. If stop collar “L” has been disturbed, turn stop collar “L” down on the trip rod to a point 1/4inch [57.2mm] from the drive housing casting.

68. Adjust stop collar “L” gradually downward, running the speed change mechanism betweensettings, until the motor belt is flush to 1/16 inch [1.6mm] out of the countershaft pulleywhen the limit switch stops downward motion.

69. Tighten the set screw in stop collar “L”.

70. Stop collars “M”, Figures 3.4 and 3.20, and “O”, Figures 3.4 and 3.21, are set to allow 1/16inch of clearance after the limit switches have tripped and the drive has drifted to a stop.

71. Close door “H”, Figure 3.3 .

M-10C 3-9

Figure 3.20 - Stop Collar Adjustment

Tp4426.

Figure 3.21 - Stop Collar Adjustment

Tp4427.

SPINDLE BRAKE

Spindle Brake Gap Adjustment

- NOTE -There should be a .010" to .013" [.25mm to .33mm] clearance between the cork in-sert and the brake drum.




3. On HLV-H machines, turn brake switch “E” to the OFF position.

4. On HLV-H machines, place lever “A” in “High” range.

On TFB-H machines, place lever “G”, Figure 3.2, in “High” range and lever “F” in “Forward”or “Reverse”.

5. On HLV-H machines, place lever “A”, Figure 3.1, in the “Stop” position and allow the spin-dle to coast to a stop.

On TFB-H machines, place lever “G”, Figure 3.2, in the “Stop” position and allow the spin-dle to coast to a stop.

- WARNING -Be sure the spindle motor has come to a complete stop before attempting towork in the motor compartment.


7. Turn adjusting screw “P”, Figure 3.22, clock-wise or counterclockwise until there is a.010" to .013" [.25mm to .33mm] clearancebetween the cork insert and the brake drum.


9. On HLV-H machines, set brake switch “E”,Figure 3.1, to the “ON” position.

On TFB-H machines, place lever “F”, Figure3.2, in the “Brake” position

10. Push “Start/Stop” pushbutton “D”, Figure 3.1,IN to turn the machine OFF.

3-10 M-10C

Figure 3.22 - Spindle Brake Adjustment

Tp4428.

Spindle Brake Insert Replacement

- WARNING -Be sure the machine is turned OFF before attempting to work in the motorcompartment.

1. Push “Start/Stop” pushbutton “D”, Figure 3.8, IN to turn the machine OFF.


3. Loosen two bolts “U”, Figure 3.8 .

4. Remove one bolt “U” to allow brake removal.

5. Remove the brake assembly for easy access to the cork insert.

6. Loosen locknut “V”.

7. Loosen keyway guide screw “W”.

8. Turn adjusting screw “P”, Figure 3.22, counterclockwise until the cork housing is free fromthe brake.

9. Push the cork insert out of the housing by means of the threaded hole in the bottom of thehousing.

- NOTE -Be sure that the new cork insert is seated firmly in the cork insert housing.

10. Install the new cork insert.

11. Replace the cork insert housing in the brake, orienting the keyway toward keyway guidescrew “W”, Figure 3.8 .

12. Turn keyway guide screw “W” clockwise until it bottoms out in the cork housing.

13. Back keyway guide screw “W” out 1/4 turn and tighten locknut “V”.

14. Reposition the brake assembly.

15. Replace mounting bolt “U” removed in step 4.

16. Tighten both mounting bolts “U”.

17. Adjust the gap between the cork insert and the brake drum according to the steps outlinedunder “Spindle Brake Gap Adjustment”, Page 3-10.

Spindle Brake Insert Lubrication

- NOTE -Do not over-oil the cork insert.

Oil the cork insert in the spindle brake with two drops of spindle oil (Mobil® Velocite® oil No. 6) asneeded. When it is dry, the cork insert will squeak when applied against the spindle motor pulley.

Allowing the cork insert to dry out will greatly reduce the life of the drive belts and cork insert.

M-10C 3-11

SPEED CHANGE FEED SCREW NUT

Removal





4. Loosen two nuts “S”, Figure 3.23, and loosen pivot screws “T” to clear feed screw nut “R”.

5. Loosen set screw and remove stop collar “J”,Figure 3.4 .

6. On HLV-H machines, place lever “A”, Figure3.1, in “Low” range.

On TFB-H machines, place lever “F”, Figure3.2, in “Forward” or “Reverse” and lever “G”in “Low” range.

- WARNING -Use extreme caution when reachinginto the drive compartment whilethe spindle motor is running.

7. Press down on pulley carrier bracket “U”,Figure 3.23, near pivot screws “T” to placethe bracket in the down position.

8. On HLV-H machines, place lever “A”, Figure3.1, in the “Stop” position.


9. Push “Start/Stop” pushbutton “D”, Figure 3.1,IN to turn the machine OFF.

10. Turn vertical screw “Q”, Figure 3.23, by handto remove feed screw nut “R”.

11. Remove half nut “V”, Figure 3.24 .

12. Remove nut “Z” to remove half nut “Y” andspring “X” from housing “W”.

3-12 M-10C

Figure 3.23 - Speed Change Feed ScrewNut

Tp4429.

Figure 3.24 - Feed Screw Nut Components

Tp4430.

Replacement

- NOTE -Do not tighten nut “Z”, Figure 3.24, until instructed to do so.

1. Replace spring “X”, half nut “Y”, and nut “Z” in housing “W”, Figure 3.24 .

2. Line up the keyway in half nut “V” with the key screw in housing “W”; then slide half nut “V”into housing “W”, until approximately 1/16 inch [1.6mm] of the half nut is protruding fromthe housing.

- NOTE -Hold half nut “V” within 1/16 inch [1.6mm] of flush with housing “W” while installingthe feed screw nut on the vertical screw.

It may be necessary to turn half nut “Y” slightly to line up the threads in both halfnuts.

3. Noting the orientation shown in Figure 3.23, replace feed screw nut “R” by turning verticalscrew “Q” by hand.

4. Tighten nut “Z”, Figure 3.24 .




7. On HLV-H machines, place lever “A” in “Low” range.

On TFB-H machines, place lever “G”, Figure 3.2, in “Low” range and lever “F” in “Forward”or “Reverse”.

- WARNING -Use extreme caution when reaching into the drive compartment while thespindle motor is running.

8. Pull up on pulley carrier bracket “U”, Figure 3.23, near pivot screws “T” to align the pivotscrews with the feed screw nut.

9. Turn pivot screws “T” into the feed screw nut housing.

10. Tighten lock nuts “S”.


- NOTE -Vertical feed screw “Q”, Figure 3.23, should turn freely by hand.

12. Try to rotate vertical feed screw “Q”, Figure 3.23, by hand.

If the vertical feed screw does not turn freely by hand, proceed to step 13.

If the vertical feed screw does turn freely by hand, proceed to step 16.

M-10C 3-13

13. Loosen lock nuts “S”.

14. Adjust pivot screws “T” so that they each apply equal side pressure on the feed screw nut.



17. Replace stop collar “J”, Figure 3.4, and turn it down on trip rod 1 inch [25.4mm] from thetop of the rod.




21. On HLV®-H machines, place lever “A”, Figure 3.1, in the “Stop” position.



SPEED CHANGE MECHANISM

Removal

1. On HLV-H machines, place lever “A”, Figure 3.1, in the “Stop” position and lever “B” in thecenter position.




On TFB-H machines, place lever “F”, Figure 3.2, in “Forward” or “Reverse” and lever “G” in“Low” range.

4. Turn speed adjustment knob “C”, Figure 3.1, to “Slower” and hold in that position until spin-dle speed stabilizes at 125 rpm.

5. On HLV-H machines, place lever “A” in the “Stop” position to stop the spindle.


6. Press “Start/Stop” pushbutton “D”, Figure 3.1, IN to turn the machine OFF.


8. Turn main disconnect switch “B”, Figure 3.25, OFF

9. Loosen two screws “A” and open power case door “C”.

10. Disconnect the three black wires connected to the bottom of T1R, T2R, and T3R on termi-nal block “D”, Figure 3.26 . (Reference 2TB)

3-14 M-10C

11. Disconnect the green ground wire, which enters the power case through the same conduit,from ground post “E”. (Reference MACH GND #3)

12. Remove conduit nut “F”, Figure 3.27, and pull the wires into the pedestal.

13. Loosen lock nuts “S”, Figure 3.23, and loosen pivot screws “T” to clear feed screw nut “R”.

- NOTE -Do not disturb mounting bracket “I”, Figure 3.28, which is factory adjusted for align-ment.

14. Remove set screw “G”, Figure 3.28 .

15. Support the speed change mechanism and remove pin “H”.

16. Remove the speed change mechanism from the pedestal.

M-10C 3-15

Figure 3.25 - Power Case (External View)

Tp4431.

Figure 3.26 - Power Case (Partial InternalView)

Tp4432.

Disassembly

1. Loosen set screw and remove stop collar “K”, Figure 3.29 .

2. Turn vertical screw “J” by hand to remove feed screw nut “L”.

3. Remove four screws “M” and cover “N”.

4. Disconnect the three (black) motor leads.

5. Remove two screws “O”, Figure 3.30, and remove the motor.

6. Remove three screws “P”, Figure 3.1, and remove the vertical screw assembly, as shownin Figure 3.2 .

3-16 M-10C

Figure 3.27 - Speed Change Conduit Nut

Tp4433.

Figure 3.28 - Speed Change MountingBracket (Rear View)

Tp4434.

Figure 3.29 - Speed Change Mechanism

Tp4435.

Figure 3.30 - Speed Change Motor

Tp4436.

- NOTE -Do not lose the nylon plug under set screw “R”, Figure 3.33 .

7. Loosen set screw “R”, Figure 3.33, and remove nut “Q” using a spanner wrench.

- NOTE -On some machine models the worm wheel has been replaced with a straight toothwheel and the shims shown in Figure 3.32 are not required.

8. Remove worm wheel “S” and key “X”, Figure 3.33 .

9. Remove the vertical screw from drive housing “V”.

10. Remove bearing “T”, spacer “U”, and shim “W”.

11. If necessary, press bearing “Y” from vertical screw shaft “Z”.

M-10C 3-17

Figure 3.31 - Feed Screw Housing

Tp4437.

Figure 3.32 - Vertical Feed Screw Removal

Tp4438.

Figure 3.33 - Variable Feed Screw Components

Tp4439.

12. Record the connections; then disconnectwires 15, 17, 18, and 20, Figure 3.34 .

13. Remove four screws “D” to remove the limitswitches and the green ground wire.

14. Loosen set screw “E” and remove stop collar“F”.

15. Remove two roll pins “G” and stop rod “A” tofree cams “B” and springs “C”.

16. Remove the motor armature, Figure 3.35 .

17. Remove nut “H” to remove worm “I”.

18. If necessary, press bearings “J” and “K” fromthe armature shaft.

3-18 M-10C

Figure 3.34 - Drive Switches and Cams

Tp4440.

Figure 3.35 - Drive Motor Components

Tp4441.

Reassembly

1. If required, press replacement bearings “J” and “K”, Figure 3.35, onto the armature shaft.

2. Replace worm “I” and nut “H”.

- NOTE -Note the orientation of wave washer “L”, which is located in the motor cap.

3. Replace motor armature.

4. Replace motor and two screws “O”, Figure 3.30 .

5. Replace the limit switches and the green ground wire with four screws “D”, Figure 3.34 .

6. Reconnect wires 15, 17, 18, and 20.

7. Replace springs “C”, cams “B”, stop rod “A”, and roll pins “G”.

8. Reconnect the three (black) motor leads.

9. If required, press bearing “Y”, Figure 3.33, onto vertical screw shaft “Z”.

10. Assemble shim “W”, vertical screw “Z”, housing “V”, spacer “U”, and bearing “T”.

- NOTE -On some machine models the worm wheel has been replaced with a straight toothwheel and the shims shown in Figure 3.32 are not required.

11. Replace key “X”, Figure 3.33, and worm wheel “S”.

- NOTE -Be sure the nylon plug is in position under set screw “R”.

12. Replace nut “Q” and tighten set screw “R”.

13. Grease worm wheel and worm with Andok® “B” grease.

14. Replace the vertical screw assembly, as shown in Figure 3.32 .

15. Replace three screws “P”, Figure 3.31 .

16. Replace cover “N” using four screws “M”, Figure 3.29 .

- NOTE -Hold half nut “V”, Figure 3.24, within 1/16 inch [1.6mm] of flush with housing “W”while installing the feed screw nut on the vertical screw.

17. Noting the orientation shown in Figure 3.23, replace feed screw nut “R” by turning verticalscrew “Q” by hand.

- NOTE -Do not tighten the lock screws in stop collars “K”, Figure 3.29, and “F”, Figure 3.34.

18. Start stop collars “K”, Figure 3.29, and “F”, Figure 3.34, onto the trip rod.

M-10C 3-19

Replacement

1. Place the speed change mechanism in the pedestal.

2. Support the speed change mechanism and install pin “H”, Figure 3.28 .

3. Replace and tighten set screw “G”.

4. Feed the wires through the conduit elbow and into the power case.

5. Secure conduit nut “F”, Figure 3.27 .

6. Reroute and connect the three black wires labeled T1R, T2R, and T3R to their correspond-ing connections on the bottom of terminal block “D”, Figure 3.26 . (Reference 2TB)

7. Connect the green ground wire, which enters the power case through the same conduit, toground post “E”. (Reference MACH GND #3)

8. Close power case door “C”, Figure 3.25, and secure two screws “A”.

9. Turn main disconnect switch “B” ON.

10. On HLV®-H machines, place lever “A”, Figure 3.1, in the “Stop” position.





- WARNING -Use extreme caution when reaching into the drive compartment while thespindle motor is running.

13. Pull up on pulley carrier bracket “U”, Figure 3.23, near pivot screws “T” to align the pivotscrews with the feed screw nut.

14. Turn the pivot screws into the feed screw nut housing.


16. On HLV-H machines, place lever “A”, Figure 3.1, in the “Stop” position.



- NOTE -Vertical feed screw “Q”, Figure 3.23, should turn freely by hand.

18. Try to rotate vertical feed screw “Q”, Figure 3.23, by hand.

If the vertical feed screw does not turn freely by hand, proceed to step 19.

If the vertical feed screw does turn freely by hand, proceed to step 22.

19. Loosen lock nuts “S”.

3-20 M-10C

20. Adjust pivot screws “T” so that they each apply equal side pressure on the feed screw nut.


- CAUTION -Make small changes in spindle speed when checking for proper drive rota-tion. The drive may jam up on the stop collars if speed change motor rota-tion is not correct. This could result in damage to the worm wheel.


23. On HLV®-H machines, place lever “A” in “Low” range.

On TFB®-H machines, place lever “F”, Figure 3.2, in “Forward” or “Reverse” and lever “G”in “Low” range.

- NOTE -When changing spindle speed, if spindle speed is to increase, the pulley assemblyshould move upward. If spindle speed is to decrease, the pulley assembly shouldmove downward.

24. Make a small change in the spindle speed by turning switch “C”, Figure 3.1, to “Faster” or“Slower” and observe the movement of the pulley assembly.

If the pulley assembly does not move in the correct direction, proceed to step 25.

If the pulley assembly moves in the correct direction, proceed to step 33.



26. Press “Start/Stop” pushbutton “D” IN to turn the machine OFF.


28. Loosen two screws “A” and open power case door “C”.

29. Interchange the two black wires connected to T1R and T2R on terminal block “D”, Figure3.26 . (Reference 2TB)

30. Close power case door “C”, Figure 3.25, and tighten two screws “A”.

31. Turn main disconnect switch “B” ON.

32. Repeat steps 22 through 24.

33. Replace stop collar “J”, Figure 3.4, and turn it down on the trip rod 1 inch [25.4mm] fromthe top of the rod.



36. If stop collar “L” has been disturbed, turn stop collar “L” down on the trip rod to a point2-1/4 inches [57.2mm] from the drive housing casting.

M-10C 3-21

37. Adjust stop collar “L” gradually downward, running the speed change mechanism betweensettings, until the motor belt is flush to 1/16 inch [1.6mm] out of the countershaft pulleywhen the limit switch stops downward motion.

38. Tighten the set screw in stop collar “L”.

39. Stop collars “M”, Figures 3.4 and 3.20, and “O”, Figures 3.4 and 3.21, are set to allow 1/16inch of clearance after the limit switches have tripped and the drive has drifted to a stop.


Lubrication

- NOTE -For proper lubrication of the drive, run the drive through the entire speed range atleast once a day.

Lubricate the feed screw nut a minimum of once a month or more often if necessary.

Apply Cosmolube® grease No. 2 at fitting “K”, Figure 3.4 . The grease is sufficient when it is forcedout of the slot in fitting “K”.

Lubricate the bearing surfaces of the countershaft with Molylube® Anti-Seize grease every threemonths.

The main drive motor and speed change motor bearings are grease packed for life and require nofurther lubrication.

PULLEY AND SHAFT ASSEMBLY

Removal











8. Remove lock nut “P”, Figure 3.5 .

3-22 M-10C

9. Raise the front of the motor mounting plate approximately two inches and block it in thisposition, as shown in Figure 3.6 .

10. Loosen two bolts “U”, Figure 3.8, and slide brake assembly “X” away from motor pulley “T”.

11. Remove motor belt “N”, Figure 3.4, from motor pulley “T”, Figure 3.8 .

12. Roll motor belt “S”, Figure 3.7, to the right off the pulley and let it rest on the pulley hub, asshown.


14. On HLV®-H machines, place lever “A” in “High” range.

On TFB®-H machines, place lever “F”, Figure3.2, in “Forward” or “Reverse” and lever “G”in “High” range.

15. Turn speed adjustment knob “C”, Figure 3.1,to “Faster” and hold in that position until pul-ley hanger assembly “Y”, Figure 3.9, reachesmaximum upward travel.

16. On HLV-H machines, place lever “A”, Figure3.1, in the “Stop” position.



18. Slide countershaft assembly “Z”, Figure 3.9,to the extreme right and remove both beltsover the left end of the countershaft.

19. Remove the snap ring from the right side ofthe pulley hanger assembly, as shown in Fig-ure 3.36 .

- NOTE -A small piece of sheet metal wrappedaround the pulley shaft can be used toremove the bearing and spacer.

20. Remove the bearing and spacer from theright side of the pulley hanger assembly, asshown in Figure 3.37 .

21. Move the pulley shaft to the right out of theleft bearing and remove the pulley and shaftassembly, as shown in Figure 3.38 .

22. If necessary, remove the snap ring to re-move the left bearing and spacer.

M-10C 3-23

Figure 3.36 - Countershaft Snap RingRemoval

Tp4442.

Figure 3.37 - Countershaft Bearing andSpacer Removal

Tp4443.

Replacement

1. If removed, install the spacer, bearing, andsnap ring in the left side of the pulleyhanger.

- NOTE -The shaft on the pulley assembly islonger on the right side, as viewedfrom the front of the machine.

2. Coat the bearing surfaces of the pulley shaftwith Molylube® Anti-Seize grease and installthe pulley assembly in the bearing in the leftside of the pulley hanger.

3. Install the spacer and bearing in the rightside of the pulley hanger, as shown in Figure3.37 .

4. Install the snap ring in the right side of thepulley hanger, as shown in Figure 3.36 .

5. Slide countershaft assembly “Z”, Figure 3.9, to the extreme right and slide the motor beltover the left end of the countershaft.

6. Position the motor belt at the right end of the pulley, resting on the pulley hub, as shown inFigure 3.7 .

7. Slide the spindle drive belt over the left end of the countershaft and position it on the leftpulley, as viewed from the front of the machine.

8. Slide countershaft assembly “Z”, Figure 3.9, to the left until the left end of the pulley shaftis positioned inside the bearing in the left side of pulley hanger “Y”.

- WARNING -Use extreme caution when running the spindle motor while pedestal door“H”, Figure 3.3, is open.








14. Position the motor belt on the right pulley, as viewed from the front of the machine.

15. Remove the wooden block and carefully lower the front of the motor mounting plate.

3-24 M-10C

Figure 3.38 - Countershaft Removal

Tp4444.

16. Install lock nut “P”, Figure 3.5, but do not tighten.

17. Adjust drive belt tension by turning adjusting screw “Q” clockwise to lower the drive motorand tighten the drive belts.


19. If it was necessary to replace the pulley and shaft assembly:

a) Turn stop collar “J”, Figure 3.4, down on trip rod 1 inch [25.4mm] from the top of therod.

b) Turn stop collar “L” down on trip rod to a point 2-1/4 inches [57.2mm] from the drivehousing casting.

20. Balance the tension on the motor and spindle belts:

a) Close door “H”, Figure 3.3 .

b) Pull “Start/Stop” pushbutton “D”, Figure 3.1, OUT to turn the machine ON.

c) On HLV®-H machines, turn brake switch “E” to the OFF position.

d) On HLV-H machines, place lever “A” in “Low” range.

On TFB®-H machines, place lever “F”, Figure 3.2, in “Forward” or “Reverse” and lever“G” in “Low” range.

e) Turn speed adjustment knob “C”, Figure 3.1, to “Faster” and hold in that position untilspindle speed stabilizes at 3000 rpm.

f) On HLV-H machines, place lever “A”, Figure 3.1, in the “Stop” position and allow thespindle to coast to a stop.

On TFB-H machines, place lever “G”, Figure 3.2, in the “Stop” position and allow thespindle to coast to a stop.

g) Press “Start/Stop” pushbutton “D”, Figure 3.1, IN to turn the machine OFF.

h) Open door “H”, Figure 3.3 .

21. Recheck motor and spindle belt tension.

If belt tension needs to be adjusted, proceed to step 22.

If belt tension does not need to be adjusted, proceed to step 25.

22. Loosen lock nut “P”, Figure 3.5 .

23. Adjust drive belt tension by turning adjusting screw “Q”:

Clockwise to lower the drive motor and tighten the drive belts.

Counterclockwise to raise the drive motor and loosen the drive belts.




M-10C 3-25



28. On HLV-H machines, turn brake switch “E”, Figure 3.1, to the ON position.

29. Turn speed adjustment knob “C” to “Slower” and hold in that position until the spindlespeed stabilizes at 125 rpm.

30. On HLV-H machines, place lever “A” in the “Stop” position.



32. If it was necessary to replace the pulley and shaft assembly:

a) Open door “H”, Figure 3.3 .

b) Pull “Start/Stop” pushbutton “D”, Figure 3.1, OUT to turn the machine ON.

c) Adjust stop collar “J”, Figure 3.4, gradually upward, running the speed change mecha-nism between settings, until the spindle belt is flush to 1/16 inch [1.6mm] out of thecountershaft pulley when the limit switch stops upward motion.

d) Tighten the set screw in stop collar “J”.

e) Adjust stop collar “L” gradually downward, running the speed change mechanism be-tween settings, until the motor belt is flush to 1/16 inch [1.6mm] out of the countershaftpulley when the limit switch stops downward motion.

f) Tighten the set screw in stop collar “L”.

g) Stop collars “M”, Figures 3.4 and 3.20, and “O”, Figures 3.4 and 3.21, are set to allow1/16 inch of clearance after the limit switches have tripped and the drive has drifted to astop.

h) Close door “H”, Figure 3.3 .

3-26 M-10C

POWER FEED DRIVE

POWER FEED CONTROL PANEL

Refer to Chapter 6 for information on the Power Feed control panel.

POWER FEED LUBRICATION

The power feed drive is lubricated with oil from the carriage apron. Refer to Chapter 1 forinformation on maintaining the proper oil level or changing the oil in the carriage apron.

DRIVE DISASSEMBLY



2. Press “Start/Stop” pushbutton “D” IN to turn the machine OFF.


4. Remove six screws “M”, Figure 3.39, and set power feed panel “N” out of control box “O”.

5. Record the connections; then disconnect wires A1 and A2 from switch “P”, Figure 3.40 .

6. Record the connection; then disconnect wire F1 from terminal block “R”, Figure 3.41 .

7. Record the connection; then disconnect wire F2 from terminal block “S”, Figure 3.42 .

8. Disconnect the power feed motor ground wire (green) from ground stud “T”.

M-10C 3-27

Figure 3.39 - Power Feed Control Box

Tp4445.

Figure 3.40 - Power Feed Module (SideView)

Tp4446.

9. Remove three bolts “U”, Figure 3.43, and pull power feed control box “V” away from theend of the bed.

10. Remove cord grip nut “Q”, Figure 3.40, and remove the power feed motor cable from thecontrol box.

- NOTE -Do not pull against the motor end ofthe cable.

11. Pull the power feed motor cable out throughgrommet “W”, Figure 3.44, in the bed.

12. Place a pan capable of holding one pint ofliquid under drain plug “A”, Figure 3.45 .

13. Remove and clean magnetic drain plug “A”.


15. Remove the drain pan and replace magneticdrain plug “A”.

16. Properly dispose of the used oil.

17. Remove three screws “X”, Figure 3.44, andremove the power feed assembly from thecarriage apron cover.

18. Remove four screws “D”, Figure 3.46, andseparate the power feed motor from wormwheel housing “F”.

3-28 M-10C

Figure 3.41 - Power Feed Module (BackView)

Tp4447.

Figure 3.42 - Power Feed Module (TopView)

Tp4448.

Figure 3.43 - Power Feed Control Box(End View)

Tp4449.

19. Remove screw “G”, Figure 3.47, and remove worm wheel and housing, Figure 3.48 .

20. Remove nut “H”, Figure 3.48, and worm wheel “I”.

21. Remove key “J”, Figure 3.49, and remove 21 tooth gear and shaft “K”.

22. Remove bearings “L”, Figure 3.50, snap rings “M”, and seals “N” from housing “O”.

M-10C 3-29

Figure 3.44 - Power Feed Drive Removal

Figure 3.45 - Magnetic Drain Plug

Tp4451.

Figure 3.46 - Power Feed Drive

Tp4452.

Tp4450.

DRIVE REASSEMBLY

1. Replace seals “N”, Figure 3.50, snap rings“M”, and bearings “L” in housing “O”.

2. Replace 21 tooth gear and shaft “K”, Figure3.49, and key “J”.

3. Replace worm wheel “I”, Figure 3.48, and nut“H”.

4. Replace worm wheel and housing, Figure3.48, and tighten screw “G”, Figure 3.47 .

5. Remount the power feed motor to the powerfeed housing and install four screws “D”, Fig-ure 3.46 .

6. Apply Permatex® sealant to the surface ofpower feed housing “Y”, Figure 3.44, that willbe against the carriage apron cover.

7. Remount the power feed assembly on thecarriage apron cover using three screws “X”.

- NOTE -Leave enough slack in the power feedmotor cable to allow the full range ofcarriage movement without putting ex-cessive strain on the cable.

8. Insert the power feed motor cable into grom-met “W”.

9. Pull the power feed motor cable out of theend of the bed.

10. Slide cord grip nut “Q”, Figure 3.40, over thepower feed motor cable.

11. Insert the power feed motor cable throughthe cord grip and into the control box.

12. Tighten cord grip nut “Q”.

13. Position control box “V”, Figure 3.43, against the end of the bed and install three bolts “U”.

14. Connect the power feed motor ground wire (green) to ground stud “T”, Figure 3.42 .

15. Connect wire F2 to terminal block “S”, as recorded during the removal procedure.

16. Connect wire F1 to terminal block “R”, Figure 3.41, as recorded during the removal proce-dure.

17. Connect wires A1 and A2 to switch “P”, Figure 3.40, as recorded during the removal proce-dure.

18. Mount power feed control panel “N”, Figure 3.39, in control box “O” using six screws “M”.

3-30 M-10C

Figure 3.47 - Retaining Screw for WormWheel Housing

Tp4453.

Figure 3.48 - Worm Wheel and Housing

Tp4454.

- NOTE -The carriage apron oil reservoir is full when sight window “B”, Figure 3.45, is com-pletely filled with oil.


a) Remove cap “C”, Figure 3.45 .


c) Replace cap “C”.

DRIVE MOTOR BRUSH REPLACEMENT





4. Remove two caps “E”, Figure 3.46 .

5. Remove the springs and motor brushes located under two caps “E”.

6. Install the new motor brushes in the drive motor.

7. Replace the springs and two caps “E”.

M-10C 3-31

Figure 3.49 - Worm Wheel Housing andComponents

Tp4455.

Figure 3.50 - Worm Wheel Housing andComponents

Tp4456.

- NOTES -

3-32 M-10C

CHAPTER 4 - GEARBOX AND HEADSTOCK

COLLET CLOSERThe collet closer should be removed weekly and

between setups for cleaning. This will help prevent abuildup of chips between the collet closer tube andthe inside of the spindle at the rear of the spindle andat the collet threads.

REMOVAL AND CLEANING

1. Press “Start/Stop” pushbutton “A”, Figure 4.1,IN to turn the machine OFF.

- NOTE -Link pin “B”, Figure 4.2, can easily beremoved by lifting it up and out.

2. Remove link pin “B”, Figure 4.2 .

3. Remove the collet closer as shown in Figure4.3 .

- NOTE -Do not turn adjusting nut “C”; it is not threaded onto the spindle.

4. Remove adjusting nut “C” by pulling it off the end of the spindle.

5. Clean the inside of the headstock spindle and the outside diameter at the rear of the spin-dle where collet closer adjusting nut “C” locates.

6. Clean the inside and outside of the collet closer tube with mineral spirits.

M-10C 4-1

Figure 4.1 - Variable Speed Control Box(HLV®-H Version Shown)

Tp4457.

Figure 4.2 - Collet Closer Link Pin

Tp4458.

Figure 4.3 - Collet Closer Removal

Tp4459.

REPLACEMENT

1. Apply a light coat of Mobil® Velocite® oil No. 6 on the rear of the headstock spindle.

- NOTE -DO NOT force adjusting nut “C”, Figure 4.3, onto the spindle. If the adjusting nutgoes on tight, remove it and examine the headstock spindle for scratches or burrs.

2. Replace adjusting nut “C”, Figure 4.3, on the end of the spindle.

3. Apply a thin coat of Mobil Velocite oil No. 6 on bearing section “D” of the collet closer.

4. Mount the collet closer on the headstock spindle.

5. Insert link pin “B”, Figure 4.2 .

GEARBOX (English)

LUBRICATION

Lubricate the gears in the gearbox every three months, or more often if necessary, with Darmex®

DX-321 grease.

If the gearbox is not shifted for long periods of time, cycle “Feed-Thread” knob “E”, Figure 4.4,three change knob “F”, and thread change handle “G” from one extreme to the other several times.

Lubricate the bushings and shafts on the change gear bracket as needed with Mobil Velocite oilNo. 6.

4-2 M-10C

Figure 4.4 - Gearbox (Front View)

Tp4460.

GEARBOX REMOVAL (English)

1. Remove the collet closer according to theprocedure outlined on Page 4-1.

2. Remove snap ring “H”, Figure 4.5, and re-move handwheel “I”.

3. Remove key “J”, Figure 4.6, washer “K”, andwasher “L”.

4. Remove covers “O” and “P”, Figure 4.7 .

5. Remove lock screw “R”, Figure 4.8, andloosen the set screw under lock screw “R”.

6. Remove lock screw “S”.

7. Unscrew shaft “T”, Figure 4.9, with a hexwrench.

8. Remove shaft “T”, Figure 4.9, and shifter fork“Q”, Figure 4.8

9. Remove taper pin “U”, Figure 4.10 .

10. Engage carriage lead screw nut “X” Figure 4.11, with carriage lead screw “Y” by rotating le-ver “W” clockwise (as viewed from the front of the machine).

11. Move the carriage approximately 1/2 inch [12.7mm] to the right using handwheel “Z”, Fig-ure 4.12 .

12. Disengage carriage lead screw nut “X” Figure 4.11, from carriage lead screw “Y” by rotat-ing lever “W” counterclockwise.

13. Remove lock nut “V”, Figure 4.10 .

14. Turn nut “A”, Figure 4.13, clockwise to remove dowel pin “B”.

M-10C 4-3

Figure 4.5 - Spindle Headwheel

Tp4461.

Figure 4.6 - Handwheel Washers and Key

Tp4462.

Figure 4.7 - Gearbox Rear Covers

Tp4463.

- NOTE -The screw removal shown in Figure 4.14 requires a long 5/16 inch hex wrench or alength of 5/16 inch hex bar stock.

15. Remove four screws located at “C”, Figures 4.13 and 4.14 .

16. Remove the gearbox by pulling it straight off the headstock. Refer to Figure 4.15 .

4-4 M-10C

Figure 4.8 - Gearbox Shifter Fork

Tp4464.

Figure 4.9 - Shifter Fork Shaft Removal

Tp4465.

Figure 4.10 - Lock Nut and Taper Pin forLead Screw

Tp4466.

Figure 4.11 - Carriage Lead Screw Nut

Tp4467.

M-10C 4-5

Figure 4.12 - Carriage Handwheel

Tp4468.

Figure 4.13 - Locating Pins and MountingBolts

Tp4469.

Figure 4.14 - Gearbox Mounting BoltRemoval

Tp4470.

Figure 4.15 - Gearbox Removal

Tp4471.

GEARBOX DISASSEMBLY (English)

1. Perform steps 1 through 16 under “GearboxRemoval”.

2. Remove snap ring “M”, Figure 4.6 .

3. Turn screw “N”, Figure 4.6, clockwise to re-move idler gear “G”, Figure 4.16 .

4. Remove three screws from hinge “E” and re-move gear guard “F”.

5. Remove stop block “H”, Figure 4.17, and re-move bearing “I”.

6. If it is necessary to remove “Feed-Thread”pinion assembly “K”:

a) Remove lock screw “J”.

b) Loosen the set screw under lock screw“J”.

c) Pull “Feed-Thread” pinion assembly “K” out of the gearbox housing.

7. f clearance is insufficient for gears “M”, Figure 4.18, to pass through cover “N”, removestuds"L" and gears “M”.

- NOTE -Label snap rings “P”, Figure 4.18, and their associated spacers for identification forproper reassembly of the gearbox. Refer also to Figure 4.19 .

8. Remove five snap rings “P”, Figure 4.18, and their associated spacers.

9. Remove five screws “O”.

4-6 M-10C

Figure 4.16 - Gearbox Assembly

Tp4472.

Figure 4.17 - Idler Shaft Rear Bearing

Tp4473.

Figure 4.18 - Gearbox Assembly

Tp4474.

10. Place shifter shaft “R”, Figure 4.20, out ofmesh as shown.

11. Tap cluster shaft “S” with a soft-faced ham-mer until it is free from cover “T”.

- NOTE -DO NOT allow the remaining shafts tolift up with cover “T” while the cover isbeing removed. If necessary, tap theshafts back down into place with asoftfaced hammer while cover “T” isbeing removed. Refer also to Figure4.21 .

12. Remove cover “T”.

13. If it is necessary to remove three change pin-ion assembly “F”, Figure 4.4:

a) Remove lock screw “U”, Figure 4.22 .

b) Loosen the set screw under lock screw“U”.

c) Pull three change pinion assembly “F”, Figure 4.4, out of the gearbox housing.

M-10C 4-7

Figure 4.19 - Shim and Snap Ring Layout Figure 4.20 - Cluster Shaft Removal fromCover

Tp4476.

Figure 4.21 - Tapping Shafts in PlaceDuring Cover Removal

Tp4477.

Tp4475.

- NOTE -USE CARE when removing tumbler and shaft assembly “V”, Figure 4.23 . Factoryinstalled spacers may be present behind this shaft assembly. These spacers canvary in thickness and MUST be in place behind the correct shaft during reassem-bly. LABEL ALL SPACERS located behind all shaft assemblies for proper reas-sembly.

14. Remove gearbox tumbler and shaft assembly “V”, Figure 4.23 .

15. Remove cluster shaft assembly “W”, Figure 4.24 .

- NOTE -USE CARE when removing clutchshaft “X”, Figure 4.25, intermediateshaft “Y”, change shaft “Z”, and re-verse shaft “A”, Figure 4.26 . Factoryinstalled spacers may be present be-hind these shaft assemblies. Thesespacers can vary in thickness andMUST be in place behind the correctshaft during reassembly. LABEL ALLSPACERS located behind all shaft as-semblies for proper reassembly.

16. Remove clutch shaft “X”, Figure 4.25, inter-mediate shaft “Y”, and change shaft “Z” si-multaneously.

4-8 M-10C

Figure 4.22 - Lock Screw for ThreeChange Pinion Assembly

Tp4478.

Figure 4.23 - Tumbler and Shaft AssemblyRemoval

Tp4479.

Figure 4.24 - Cluster Shaft AssemblyRemoval

Tp4480.

- NOTE -Reverse shaft “A”, Figure 4.26, is of one piece construction, with the exception ofthe bearings that are pressed on each end of the shaft.

17. Remove reverse shaft “A”, Figure 4.26 .

18. To disassemble the “Feed Thread” or three change pinion gear assembly:

a) Remove set screw “E”, Figure 4.27 .

b) Remove pinion shaft “B” and handle “F” from bushing “C”.

c) Remove plunger “D” and spring “G” from handle “F”.

M-10C 4-9

Figure 4.25 - Clutch Shaft, IntermediateShaft, and Change Shaft Removal

Tp4481.

Figure 4.26 - Reverse Shaft Removal

Tp4482.

Figure 4.27 - Pinion Assembly Components

Tp4483.

19. To disassemble the gearbox tumbler and shaft assembly:

a) Press bearing “H”, Figure 4.28, off tumbler shaft “P” and remove the tumbler shaft.

b) Remove two screws “I”.

c) Remove two bearings “J”, gear “N”, and key “O”.

d) Loosen set screw “L”.

e) Remove shaft “K” to remove gear and bearing “M”.

f) Remove ball handle “Q”, Figure 4.29, nut “R”, spring “S”, plunger “T” and bushing “U”.

20. To disassemble the cluster shaft assembly:

a) Remove stud “A”, Figure 4.30, gear “B”,and spacer “C”.

b) Remove key “D” and collar “E”.

c) Remove nut “F”.

d) Remove bearing “G”.

e) Remove the 22, 23, 24, 26, 28, 32, 36,40, and 54 tooth gears.

f) Remove key “H” and spacer “J”.

g) Press bearing “K” off the shaft.

4-10 M-10C

Figure 4.28 - Tumbler and Shaft Assembly

Tp4484.

Figure 4.29 - Plunger Assembly

Tp4485.

21. To disassemble the clutch shaft assembly:

a) Press bearing “A”, Figure 4.31, off the shaft.

b) Remove nut “B” to remove reverse gear assembly “C”.

c) Remove nut “D” to remove bearing “E” from gear assembly “C”.

d) Remove clutch “G” and clutch bushing “F”.

e) Remove forward gear assembly “H” and key “L”.

f) Remove nut “J” to remove bearing “K” from forward gear assembly “H”.

g) If necessary, press bearing “M” off the shaft.

M-10C 4-11

Figure 4.30 - Cluster Shaft Assembly

Tp4486.

Figure 4.31 - Clutch Shaft Assembly

Tp4487.

- NOTE -Gears “C” and “D”, Figure 4.32, are pinned together.

22. To disassemble the intermediate shaft assembly:

a) Press gear “A”, Figure 4.32, and bearing “B” off the shaft.

b) Press gears “C” and “D”, bushing “E”, and bearing “F” off the shaft.

c) Press gear “G” off the shaft.

d) If necessary, remove keys “H” and “J”.

- NOTE -Gears “G”, Figure 4.33, are pinned together.

23. To disassemble the change shaft assembly:

a) Remove stud “A”, Figure 4.33, gear “B”, and spacer “C”.

b) Press gear “D” and bearing “E” off the shaft.

c) Remove two gears “G” and worm “F”.

d) Remove snap ring “H” and press bearing “J” off the shaft.

e) If necessary, remove keys “K”, “L”, “M”, and the key located in the inside diameter ofworm “F”.

4-12 M-10C

Figure 4.32 - Intermediate Shaft Assembly

Tp4488.

Figure 4.33 - Change Shaft Assembly

Tp4489.

GEARBOX REASSEMBLY (English)

- NOTE -Gears “G”, Figure 4.33, are pinned together.

1. To reassemble the change shaft assembly:

a) If removed, replace keys “K”, “L”, “M”, Figure 4.33, and the key located in the inside di-ameter of worm “F”.

b) Press bearing “J” onto the shaft and replace snap ring “H”.

c) Replace worm “F” and two gears “G”.

d) Press gear “D” and bearing “E” onto the shaft.

e) Replace spacer “C”, gear “B”, and stud “A”.

- NOTE -Gears “C” and “D”, Figure 4.32, are pinned together.

2. To reassemble the intermediate shaft assembly:

a) If removed, replace keys “H” and “J”, Figure 4.32 .

b) Press gear “G” onto the shaft.

c) Press gears “C” and “D” onto the shaft.

d) Press bushing “E” and bearing “F” onto the shaft.

e) Press bearing “B” and gear “A” onto the shaft.

3. To reassemble the clutch shaft assembly:

a) If removed, press bearing “M”, Figure 4.31, onto the shaft.

b) Replace bearing “K” and nut “J” on forward gear assembly “H”.

c) Replace key “L” and forward gear assembly “H”.

d) Replace clutch bushing “F” and clutch “G”.

e) Replace bearing “E” and nut “D” on reverse gear assembly “C”.

f) Replace reverse gear assembly “C” and nut “B”.

g) Press bearing “A” onto the shaft.

4. To reassemble the cluster shaft assembly:

a) Press bearing “K”, Figure 4.30, onto the shaft.

b) Replace spacer “J” and key “H”.

c) Replace the 54, 40, 36, 32, 28, 26, 24, 23, and 22 tooth gears.

d) Replace bearing “G”.

e) Replace nut “F”.

f) Replace collar “E” and key “D”.

g) Replace spacer “C”, gear “B”, and stud “A”.

M-10C 4-13

5. To reassemble the gearbox tumbler and shaft assembly:

a) Replace bushing “U”, Figure 4.29, plunger “T”, spring “S”, nut “R”, and ball handle “Q”.

b) Hold gear and bearing “M”, Figure 4.28, in position and replace shaft “K”.

c) Tighten set screw “L”.

d) Replace key “O”, gear “N”, and two bearings “J”.

e) Replace two screws “I”.

f) Replace tumbler shaft “P”.

g) Press bearing “H” onto shaft “P”.

6. To reassemble the “Feed-Thread” or three change pinion assembly:

a) Replace spring “G”, Figure 4.27, and plunger “D” in handle “F”.

b) Slide pinion shaft “B” through bushing “C” and replace handle “F”.

c) Replace and tighten set screw “E”.

- NOTE -Factory installed spacers may have been present behind clutch shaft “X”, Figure4.25, intermediate shaft “Y”, change shaft “Z”, or reverse shaft “A”, Figure 4.26 .These spacers can vary in thickness and must be in place behind the correct shaftduring reassembly. Replace these spacers as labeled during disassembly.

7. Replace the spacers in the gearbox housing as labeled during disassembly.

- NOTE -As they are installed, gently tap reverse shaft “A”, Figure 4.26, clutch shaft “X”, Fig-ure 4.25, intermediate shaft “Y”, and change shaft “Z” into place with a soft-facedhammer.

8. Install reverse shaft “A”, Figure 4.26, and gently tap it into place.

9. Install clutch shaft “X”, Figure 4.25, intermediate shaft “Y”, and change shaft “Z” simulta-neously; then gently tap them into place.

- NOTE -When replacing the cluster shaft, position bearing “D”, Figure 4.15, midway in thecasting as shown.

10. Replace cluster shaft assembly “W”, Figure 4.24 .

- NOTE -Factory installed spacers may have been present behind tumbler and shaft assem-bly “V”, Figure 4.23 . These spacers can vary in thickness and must be in placebehind this shaft assembly during reassembly. Replace these spacers as labeledduring disassembly.

11. Install tumbler and shaft assembly “V”, Figure 4.23, and gently tap it into place.

4-14 M-10C

12. If removed, install three change pinion assembly “F”, Figure 4.4 :

a) Replace the three change pinion assembly in the gearbox housing.

b) Tighten the set screw under lock screw “U”, Figure 4.22 .

c) Replace and tighten lock screw “U”.

- CAUTION -Use care that all components are properly aligned with the holes in cover“T”, Figure 4.21, as the cover is being mounted on the gearbox housing.

13. “T”, Figure 4.21, and tap slowly into place using a soft-faced hammer.

14. Replace five screws “O”, Figure 4.18 .

- NOTE -Spacers “Q”, Figure 4.19, and snap rings “P” MUST be installed properly. Refer tothe labels that were attached during disassembly.

15. Install spacers “Q”, Figure 4.19, and five snap rings “P”, Figures 4.18 and 4.19.

16. Remount gear guard “F”, Figure 4.16, using three screws in hinge “E”.

- NOTE -When installing the “Feed-Thread” pinion assembly, line up timing mark “N”, Figure4.34, on the worm gear and timing mark “O” on the pinion.

17. If removed, replace “Feed-Thread” pinion assembly “K”, Figure 4.17:

a) Replace the “Feed-Thread” pinion assembly in the gearbox housing.

b) Tighten the set screw under lock screw “J”.

c) Replace and tighten lock screw “J”.

M-10C 4-15

Figure 4.34 - Timing Marks for Worm Gearand Pinion

Tp4490.

Figure 4.35 - Checking Three ChangeGear Position

Tp4491.

18. Replace bearing “I” and stop block “H”.

19. Replace idler gear “G”, Figure 4.16, and screw “N”, Figure 4.6.

20. Replace snap ring “M”, Figure 4.6.

21. Turn three change" handle “F”, Figure 4.4, to the “3" position.

22. Check gears “P”, Figure 4.35, and “Q” to be sure they mesh properly.

If the gears mesh properly, this reassembly procedure is complete.

If the gears do not mesh properly, go to step 21.

23. Loosen set screw “E”, Figure 4.27 .

24. Position gears “P”, Figure 4.35, and “Q” as shown.

25. With plunger “D”, Figure 4.27, in the notched position, press against pinion “R”, Figure

GEARBOX REPLACEMENT (English)

1. Position the gearbox as shown in Figure 4.15.

- NOTE -If resistance is met while pushing the gearbox into position, bearing “D”, Figure4.15, may not be positioning properly.

2. Hold lock nut “V”, Figure 4.10, in position and carefully push the gearbox into position.

- NOTE -Screw replacement shown in Figure 4.14 requires a long 5/16 inch hex wrench ora length of 5/16 inch hex stock.

3. Replace four screws “C”, Figures 4.13 and 4.14 .

4. Back off nut “A”, Figure 4.13, and replace dowel pin “B”.

5. Tighten lock nut “V”, Figure 4.10 to 300 lb-in [33.9 Nm].


- NOTE -Properly align the tapered hole in the left end of carriage lead screw “Y” with thecorresponding hole in the gearbox cluster shaft.

7. Move the carriage to the left using handwheel “Z”, Figure 4.12, to line up the holes in thelead screw and the cluster shaft for taper pin “U”, Figure 4.10 .

8. Disengage carriage lead screw nut “X” Figure 4.11, from carriage lead screw “Y” by rotat-ing lever “W” counterclockwise.

9. Install taper pin “U”, Figure 4.10 .

4-16 M-10C

- NOTE -When replacing shifter yoke “Q”, Figure 4.8, place the shifter fork in the groove ofclutch “G”, Figure 4.31 .

10. Replace shifter yoke “Q”, Figure 4.8, and shaft “T”, Figure 4.9 .

11. Locate the shifter yoke on the shaft by lining up the screw holes.

- NOTE -The set screw under lock screw “R”, Figure 4.8, is a dog point screw and must lo-cate in the hole in shaft “T”, Figure 4.9 .

12. Tighten the set screw located under lock screw “R”, Figure 4.8 .

13. Replace lock screws “R” and “S”.

14. Replace covers “O” and “P”, Figure 4.7 .

15. Replace washers “L” and “K”, Figure 4.6, and key “J”.

16. Replace handwheel “I”, Figure 4.5, and snap ring “H”.

17. Remount the collet closer according to the procedure starting on Page 4-2.

M-10C 4-17

GEARBOX (English-Metric)

LUBRICATION

Lubricate the gears in the gearbox every three months, or more often if necessary, with Darmex®

DX-321 grease.

If the gearbox is not shifted for long periods of time, cycle “Feed-Thread” knob “A”, Figure 4.36,English-Metric knob “B”, three change knob “C”, and thread change handle “D” from one extreme tothe other several times.

Lubricate the bushings and shafts on the change gear bracket as needed with Mobil® Velocite®

No. 6 oil.

4-18 M-10C

Figure 4.36 - Gearbox (Front View)

Tp4492.

GEARBOX REMOVAL (English-Metric)

1. Remove the collet closer according to theprocedure outlined on Page 4-1.

2. Remove snap ring “H”, Figure 4.5, and re-move handwheel “I”.

3. Remove key “J”, Figure 4.6, washer “K”, andwasher “L”.

4. Remove covers “E” and “F”, Figure 4.37.

5. Remove lock screw “I”, Figure 4.38, andloosen the set screw under lock screw “I”.

6. Remove lock screw “J”.

7. Unscrew shaft “K”, Figure 4.39, with a hexwrench.

8. Remove shaft “K”, Figure 4.39, and shifterfork”H”, Figure 4.38 . Refer also to Figure4.40 .

9. Remove taper pin “U”, Figure 4.10 .


11. Move the carriage approximately 1/2 inch [12.7mm] to the right using handwheel “Z”, Fig-ure 4.12 .

12. Disengage carriage lead screw nut “X” Figure 4.11, from carriage lead screw “Y” by rotat-ing lever “W” counterclockwise (as viewed from the front of the machine).

13. Remove lock nut “V”, Figure 4.10 .

M-10C 4-19

Figure 4.37 - Gearbox Rear Covers

Figure 4.38 - Gearbox Shifter Fork

Tp4494.

Figure 4.39 - Gearbox Assembly (EndView)

Tp4495.

Tp4493.

14. Turn nut “A”, Figure 4.13, clockwise to remove dowel pin “B”.

- NOTE -The screw removal shown in Figure 4.14 requires a long 5/16 inch hex wrench or alength of 5/16 inch hex bar stock.

15. Remove four screws located at “C”, Figures 4.13 and 4.14 .

16. Remove the gearbox by pulling it straight off the headstock. Refer to Figure 4.41 .

GEARBOX DISASSEMBLY (English-Metric)

1. Perform steps 1 through 16 under “GearboxRemoval”.

2. Remove snap ring “M”, Figure 4.6 .

3. Turn screw “N”, Figure 4.6, clockwise to re-move idler gear “L”, Figure 4.39 .

4. If possible, remove cluster shaft extension“G”, Figure 4.37 .

5. Remove stop block “R”, Figure 4.42, andbearing “S”.

6. If it is necessary to remove “Feed-Thread”pinion assembly “T”:

a) Remove lock screw “U” .

b) Loosen the set screw under lock screw“U”.

c) Pull “Feed-Thread” pinion assembly “T”out of the gearbox housing.

4-20 M-10C

Figure 4.40 - Shifter Fork Shaft Removal

Tp4496.

Figure 4.41 - Gearbox Removal

Tp4497.

Figure 4.42 - Idler Shaft Rear Bearing

Tp4498.

7. Remove three screws “O”, Figure 4.39, and remove gear guard “P”.

- NOTE -Tag gears “N”, Figure 4.39, and “B”, Figure 4.43, as they are removed to ensureproper reassembly of the gearbox.

8. Loosen the lock screws in studs “M”, Figure 4.39; then, remove studs “M”, gears “N”, andthe keys located under gears “N”.

9. Loosen the lock screws in studs “A”, Figure 4.43; then, remove studs “A”, gears “B”, andthe keys located under gears “B”.

- NOTE -Label six snap rings “C” and their associated spacers as they are removed foridentification to ensure proper reassembly of the gearbox.

10. Remove six snap rings “C” and their associated spacers.

11. Remove five screws “D”.

12. Place tumbler shaft “H”, Figure 4.44, out of mesh.

- NOTES -DO NOT allow the remaining shafts to lift up with cover “F” and cluster shaft “G”while they are being removed. If necessary, tap the shafts back down into placewith a soft-faced hammer while cover “F” and cluster shaft “G” are being removed.

English-Metric gear “K”, Figure 4.46, will drop down slightly when both cluster shaft“G”, Figure 4.44, and cluster shaft extension “G”, Figure 4.37, have been removed.

13. Remove cover “F”, Figure 4.44, and cluster shaft “G”.

14. Remove nut “E”, Figure 4.43, to remove cluster shaft “G”, Figure 4.44, from cover “F”.

M-10C 4-21

Figure 4.43 - Gears and Mounting Studs

Tp4499.

Figure 4.44 - Cover and Cluster ShaftRemoval

Tp4500.

- NOTE -To remove cluster shaft extension “G”, Figure 4.37 It may be necessary to tap atpoint “J”, Figure 4.44, with a piece of wood.

15. If it was not possible to do so before, remove cluster shaft extension “G”, Figure 4.37 .

- NOTE -USE CARE when removing tumbler and shaft assembly “H”, Figure 4.44 . Factoryinstalled spacers may be present behind this shaft assembly. These spacers canvary in thickness and MUST be in place behind the correct shaft during reassem-bly. LABEL ALL SPACERS located behind all shaft assemblies for proper reas-sembly.

16. Pull plunger “I”, Figure 4.44, out and remove gearbox tumbler and shaft assembly “H”. Re-fer also to Figure 4.45 .

- NOTE -USE CARE when removing three change shaft “P”, Figure 4.46, metric conversionshaft “L”, intermediate shaft “M”, clutch shaft “N”, and reverse shaft “O”. Factory in-stalled spacers may be present behind these shaft assemblies. These spacers canvary in thickness and MUST be in place behind the correct shaft during reassem-bly. LABEL ALL SPACERS located behind all shaft assemblies for proper reas-sembly.

17. Remove English-Metric gear “K”, Figure 4.46, by pulling it down and out.

18. Remove three change shaft “P”, Figures 4.46 and 4.47 .

19. Remove metric conversion shaft “L”, Figures 4.46 and 4.48 .

20. Remove intermediate shaft “M” and clutch shaft “N”, Figures 4.46 and 4.49, at the sametime.

4-22 M-10C

Figure 4.45 - Tumbler and Shaft AssemblyRemoval

Tp4501.

Figure 4.46 - English/Metric Gear Removal

Tp4502.

- NOTE -Reverse shaft “O”, Figures 4.46 and 4.50, is of one piece construction, with the ex-ception of the bearings that are pressed on each end of the shaft.

21. Remove reverse shaft “O”, Figures 4.46 and4.50 .

22. If it is necessary to remove three change pin-ion assembly “C”, Figure 4.36:

a) Remove lock screw “Q”, Figure 4.50 .

b) Loosen the set screw under lock screw“Q”.

c) Pull three change pinion assembly “C”,Figure 4.36, out of the gearbox housing.

23. If it is necessary to remove “English-Metric”pinion assembly “B”, Figure 4.36:

a) Remove lock screw “V”, Figure 4.42 .

b) Loosen the set screw under lock screw“V”.

c) Pull “English-Metric” pinion assembly “B”,Figure 4.36, out of the gearbox housing.

M-10C 4-23

Figure 4.47 - Three Change ShaftAssembly Removal

Tp4503.

Figure 4.48 - Metric Conversion ShaftAssembly Removal

Tp4504.

Figure 4.49 - Clutch Shaft AssemblyRemoval

Tp4505.

24. To disassemble the “Feed-Thread” pinion assembly:

a) Remove set screw “E”, Figure 4.27 .

b) Remove pinion shaft “B” and handle “F” from bushing “C”.

c) Remove plunger “D” and spring “G” from handle “F”.

25. To disassemble the “English-Metric” pinionassembly:

a) Remove set screw “U”, Figure 4.51 .

b) Remove pinion shaft “R” and handle “T”from bushing “S”.

c) Remove plunger “W” and spring “V” fromhandle “T”.

26. To disassemble the three change pinion as-sembly:

a) Remove set screw “D”, Figure 4.52 .

b) Remove pinion shaft “A” and handle “C”from bushing “B”.

c) Remove plunger “F” and spring “E” fromhandle “C”.

4-24 M-10C

Figure 4.50 - Reverse Shaft AssemblyRemoval

Tp4506.

Figure 4.51 - English-Metric Pinion Assembly

Tp4507.

- NOTE -Stud “G”, gear “H”, and key “S”, Figure 4.53, were removed in step 9.

27. To disassemble the gearbox tumbler and shaft assembly:

a) Remove spacer “I”, Figure 4.53 .

b) _ the tumbler shaft.

c) Remove pin “P”; then, press gear “Q” and bearing “R” from the tumbler shaft.

d) Loosen set screw “M”.

e) Remove shaft “N” to remove gear and bearing “L”.

f) If necessary, press two bearings “T”, from tumbler body “K” .

g) Remove ball handle “U”, Figure 4.54, nut “V”, spring “W”, plunger “X” and bushing “Y”.

M-10C 4-25

Figure 4.52 - Three Change Pinion Assembly

Tp4508.

Figure 4.53 - Tumbler and Shaft Assembly

Tp4509.

- NOTES -Nut “E”, Figures 4.43 and 4.55, was removed in step 14.

Bearing “D”, Figure 4.55, and spacers are located under nut “E”, Figures 4.43 and4.55, and is held in cover “F”, Figure 4.43, by two retaining rings.

28. To disassemble the cluster shaft assembly:

a) If necessary, remove bearing “D” and spacers from cover “F”, Figure 4.43 . Label spac-ers for proper reassembly.

c) Remove the 22, 23, 24, 26, 28, 30, 32, 35, 36, 38, 40, and 50 tooth gears, Figure 4.55 .

d) Remove key “A”.

e) If necessary, remove bearing “B” from the end of shaft “C”.

4-26 M-10C

Figure 4.54 - Plunger Assembly Components

Tp4510.

Figure 4.55 - Cluster Shaft Assembly

Tp4511.

- NOTE -Note the orientation of nut “G”, Figure 4.56, before removing it.

29. To disassemble the cluster shaft extension:

a) Remove spacer “F”, Figure 4.56 .

b) Remove nut “G”, Figure 4.56, and press bearing “Q”, Figures 4.41 and 4.56, from theshaft.

30. To disassemble the clutch shaft assembly:

a) Press bearing “I”, Figure 4.57, off the shaft.

b) Remove nut “J” to remove forward gear assembly “M”.

c) Remove nut “K” to remove bearing “L” from forward gear assembly “M”.

d) Remove quick reverse assembly “N”.

e) Remove key “S”, and reverse gear assembly “O”.

f) Remove nut “Q”, to remove bearing “P”, from reverse gear assembly “O”.

g) If necessary, press bearing “R”, off the shaft.

M-10C 4-27

Figure 4.56 - Cluster Shaft Extension

Tp4512.

Figure 4.57 - Clutch Shaft Assembly

Tp4513.

- NOTE -Gears “U” and “V”, Figure 4.58, are pinned together. DO NOT separate gears “U”and “V”.

31. To disassemble the intermediate shaft assembly:

a) Press gears “U” and “V”, Figure 4.58, and bearing “T” from the shaft.

b) Press gears “W” and “X” from the shaft.

c) Remove key “Z”.

d) If necessary, press bearing “Y” off the shaft.

- NOTES -Gears “F” and “G”, Figure 4.59, are pinned together. DO NOT separate thesegears.

Stud “A”, gear “B”, and key “P” were removed in step 9.

Key “N” is located between worm “O” and gears “F” and “G”.

32. To disassemble the three change shaft assembly:

a) Remove spacer “C”, Figure 4.59 .

b) Press bearing “D” from the shaft.

c) Press bearing “L” from the shaft.

d) Remove worm “K” with fork “J”, bearings “I”, and snap ring and spacer “H” still attached.

e) Remove snap ring and spacer “H” and fork “J” from worm “K”.

f) If necessary, press bearings “I” from fork “J”.

g) Remove worm “O” and two gears “F” and “G” from the shaft.

h) If necessary, remove two gears “F” and “G” and key “N” from worm “O”.

i ) If necessary, remove key “E” from the inside diameter of worm “O” and remove key “M”from the inside diameter of worm “K”.

4-28 M-10C

Figure 4.58 - Intermediate Shaft Assembly

Tp4514.

- NOTE -Stud “M”, gear “N”, and key “Q”, Figures 4.39 and 4.60, were removed in step 8.

33. To disassemble the metric conversion shaft assembly:

a) Remove spacer “O”.

b) Press bearing “P” off the shaft.

c) Remove pin “R”.

d) Press gear “T” and bearing “S” off the shaft.

M-10C 4-29

Figure 4.59 - Three Change Shaft Assembly

Tp4515.

Figure 4.60 - Metric Conversion Shaft Assembly

Tp4516.

GEARBOX REASSEMBLY (English-Metric)

- NOTES -During reassembly, line up the hole in gear “T”, Figure 4.60, with the hole in theshaft.

Stud “M”, gear “N”, and key “Q” will be replaced in step 26.

1. To reassemble the metric conversion shaft assembly:

a) Press gear “T” and bearing “S” onto the shaft.

b) Replace pin “R”.

c) Press bearing “P” onto the shaft.

d) Replace spacer “O”.

- NOTES -Stud “A”, Figure 4.59, gear “B”, and key “P” will be replaced in step 25.

Gears “F” and “G” are pinned together.

2. To reassemble the three change shaft assembly:

a) If removed, replace key “E”, Figure 4.59, in the inside diameter of worm “O” and replacekey “M” in the inside diameter of worm “K”.

b) If removed, replace key “N” and two gears “F” and “G” on worm “O”.

c) Replace worm “O” on the shaft.

d) If removed, press two bearings “I” into fork “J”.

e) Replace fork “J”, the snap ring, and spacer “H” onto worm “K”.

f) Replace worm “K” on the shaft.

g) Press bearing “L” onto the shaft.

h) Press bearing “D” onto the shaft.

i) Replace spacer “C”.

- NOTE -Gears “U” and “V”, Figure 4.53, are pinned together.

3. To reassemble the intermediate shaft assembly:

a) If removed, press bearing “Y”, Figure 4.58, onto the shaft.

b) Replace key “Z”.

c) Press gears “W” and “X” onto the shaft.

d) Press bearing “T” and gears “U” and “V” onto the shaft.

4-30 M-10C

4. To reassemble the clutch shaft assembly:

a) If removed, press bearing “R”, Figure 4.57, onto the shaft.

b) Replace bearing “P” and nut “Q” in reverse gear assembly “O”.

c) Replace reverse gear assembly “O”.

d) Replace key “S”.

e) Replace quick reverse assembly “N”.

f) Replace bearing “L” and nut “K” in forward gear assembly “M”.

g) Replace forward gear assembly “M” and nut “J”.

h) Press bearing “I” onto the shaft.

- NOTE -Bearing “Q”, Figure 4.56, locates against shoulder “H”.

5. To reassemble the cluster shaft extension:

a) Press bearing “Q”, Figure 4.56, onto the shaft.

b) Replace nut “G”, noting that the nut is oriented correctly.

c) Replace spacer “F”.

- NOTE -Bearing “B”, Figure 4.55, MUST be installed with the rounded end toward the in-side and the flat end toward the outside.

6. To reassemble the cluster shaft assembly:

a) If removed, press bearing “B”, Figure 4.55, into the end of shaft “C”.

b) Replace key “A”.

c) Replace the 50, 40, 38, 36, 35, 32, 30, 28, 26, 24, 23, and 22 tooth gears.

d) If removed, replace bearing “D”, Figure 4.55, and spacers in cover “F”, Figure 4.43 .

e) Install cluster shaft “G”, Figure 4.44, in cover “F” and replace nut “E”, Figure 4.43 .

M-10C 4-31

- NOTE -Stud “G”, Figure 4.53, gear “H”, and key “S” will be replaced in step 25. Refer alsoto Figure 4.43 .

7. To reassemble the gearbox tumbler and shaft assembly:

a) Replace bushing “Y”, Figure 4.54, plunger “X”, spring “W”, nut “V”, and ball handle “U”.

b) If removed, press two bearings “T”, Figure 4.53, into tumbler body “K”.

c) Hold gear and bearing “L” in position and replace shaft “N”.

d) Tighten set screw “M”.

e) Press gear “Q” and bearing “R” onto tumbler shaft “O” and replace pin “P”.

f) Slide tumbler shaft “O” through tumbler body “K”.

g) Press bearing “J” onto tumbler shaft “O”.

h) Replace spacer “I”.

8. To reassemble the “Feed-Thread” pinion assembly:

a) Replace spring “G”, Figure 4.27, and plunger “D” in handle “F”.

b) Slide pinion shaft “B” through bushing “C” and replace handle “F”.

c) Replace and tighten set screw “E”.

9. To reassemble the “English-Metric” pinion assembly:

a) Replace spring “V”, Figure 4.51, and plunger “W” in handle “T”.

b) Slide pinion shaft “R” through bushing “S” and replace handle “T”.

c) Replace and tighten set screw “U”.

10. To reassemble the three change pinion assembly:

a) Replace spring “E”, Figure 4.52, and plunger “F” in handle “C”.

b) Slide pinion shaft “A” through bushing “B” and replace handle “C”.

c) Replace and tighten set screw “D”.

11. Install “English-Metric” pinion assembly “B”, Figure 4.36:

a) Replace the “English-Metric” pinion assembly in the gearbox housing.

b) Tighten the set screw under lock screw “V”, Figure 4.42 .

c) Replace and tighten lock screw “V”.

12. Install three change pinion assembly “C”, Figure 4.36 :

a) Replace the three change pinion assembly in the gearbox housing.

b) Tighten the set screw under lock screw “Q”, Figure 4.50 .

c) Replace and tighten lock screw “Q”.

4-32 M-10C

- NOTE -Factory installed spacers may have been present behind reverse shaft “O”, Figure4.46, clutch shaft “N”, intermediate shaft “M”, metric conversion shaft “L”, or threechange shaft “P”. These spacers can vary in thickness and MUST be in place be-hind the correct shaft during reassembly. Replace these spacers as labeled duringdisassembly.

13. Replace spacers in the mounting side of the gearbox housing as labeled during disassem-bly.

- NOTE -As they are installed, gently tap reverse shaft “O”, Figure 4.46, clutch shaft “N”, in-termediate shaft “M”, metric conversion shaft “L”, and three change shaft “P” intoplace with a soft-faced hammer.

14. Install reverse shaft “O”, Figures 4.46 and 4.50, and gently tap into place.

15. Install clutch shaft “N” and intermediate shaft “M”, Figures 4.46 and 4.49, at the same time;then, gently tap both shafts into place.

16. Replace metric conversion shaft “L”, Figures 4.46 and 4.48, and gently tap into place.

17. Replace three change shaft “P”, Figures 4.46 and 4.47, and gently tap into place.

18. Replace English-Metric gear “K”, Figure 4.46, in the fork on the three change shaft.

19. Align English-Metric gear “K” with the cluster shaft mounting hole.

- NOTE -Factory installed spacers may have been present behind tumbler and shaft assem-bly “H”, Figure 4.44 . These spacers can vary in thickness and MUST be in placebehind this shaft assembly during reassembly.

20. Replace any spacers removed during the removal of tumbler and shaft assembly “H”, Fig-ure 4.44 .

21. Pull plunger “I” out and install tumbler and shaft assembly “H” and gently tap into place.Refer also to Figure 4.45 .

- CAUTION -Use care that all components in the gearbox are properly aligned with theholes in cover “F”, Figure 4.43, and cluster shaft “G”, Figure 4.44, is alignedwith the English-Metric gear located at point “J” before the cover is mountedon the gearbox housing.

22. Mount cover “F”, Figures 4.43 and 4.44, and tap slowly into place using a soft-faced ham-mer.

23. Replace five screws “D”, Figure 4.43 .

- NOTE -Spacers and snap rings “C”, Figure 4.43, MUST be installed properly. Refer to thelabels that were attached during disassembly.

24. Install spacers and six snap rings “C”, Figures 4.43 .

25. Replace the keys located under gears “B”, gears “B”, and studs “A”.

M-10C 4-33

26. Replace the keys located under gears “N”, Figure 4.39, gears “N”, and studs “M”.

27. Install cluster shaft extension “G”, Figure 4.37 .

28. Remount gear guard “P”, Figure 4.39, using three screws “O”.

- NOTE -When installing the “Feed-Thread” pinion assembly, line up timing mark “N”, Figure4.34, on the worm gear and timing mark “O” on the pinion.

29. Install the “Feed-Thread” pinion assembly:

a) Replace the “Feed-Thread” pinion assembly in the gearbox housing.

b) Tighten the set screw under lock screw “U”, Figure 4.42 .

c) Replace and tighten lock screw “U”.

30. Replace bearing “S”, Figure 4.42, and stop block “R”.

31. Replace idler gear “L”, Figure 4.39, and screw “N”, Figure 4.6 .

32. Replace snap ring “M”, Figure 4.6 .

33. Turn three change handle “C”, Figure 4.36, to the “3" position.

34. Check gears “P”, Figure 4.35, and “Q” to be sure they mesh properly.

If the gears mesh properly, this reassembly procedure is complete.

If the gears do not mesh properly, go to step 35.

35. Loosen set screw “E”, Figure 4.27 .

36. Position gears “P”, Figure 4.35, and “Q” as shown.

37. With plunger “D”, Figure 4.27, in the notched position, press against pinion “R”, Figure4.35, and knob “F”, Figure 4.27, and tighten set screw “E”.

4-34 M-10C

GEARBOX REPLACEMENT (English-Metric)

1. Position the gearbox as shown in Figure 4.41 .

- NOTE -If resistance is met while pushing the gearbox into position, bearing “Q”, Figure4.41, may not be positioning properly.

2. Hold lock nut “V”, Figure 4.10, in position and carefully push the gearbox into position.

- NOTE -Screw replacement shown in Figure 4.14 requires a long 5/16 inch hex wrench ora length of 5/16 inch hex stock.

3. Replace four screws located at “C”, Figures 4.13 and 4.14 .

4. Back off nut “A”, Figure 4.13, and replace dowel pin “B”.

5. Tighten lock nut “V”, Figure 4.10, to 300 lb-in [33.9 Nm].


- NOTE -Properly align the tapered hole in the left end of carriage lead screw “Y” with thecorresponding hole in the gearbox cluster shaft.

7. Move the carriage to the left using handwheel “Z”, Figure 4.12, to line up the holes in thelead screw and the cluster shaft for taper pin “U”, Figure 4.10 .

8. Install taper pin “U”, Figure 4.10 .

9. Disengage carriage lead screw nut “X” Figure 4.11, from carriage lead screw “Y” by rotat-ing lever “W” counterclockwise (as viewed from the front of the machine).

- NOTE -When replacing shifter yoke “H”, Figure 4.38, place the shifter fork in the groove ofquick reverse assembly “N”, Figure 4.57 .

10. Replace shaft “K”, Figure 4.39, and shifter yoke “H”, Figure 4.38 .

11. Locate the shifter yoke on the shaft by lining up the screw holes.

- NOTE -The set screw under lock screw “I”, Figure 4.38, is a dog point screw and must lo-cate in the hole in shaft “K”, Figure 4.39 .

12. Tighten the set screw located under lock screw “I”, Figure 4.38 .

13. Replace lock screws “I” and “J”.

14. Replace covers “E” and “F”, Figure 4.37 .




M-10C 4-35

GEAR CHANGE BRACKET (English)

DISASSEMBLY

1. Remove bolt “A”, Figures 4.61 and 4.62 .

2. Remove gear “B”, spacer “C”, gear “D”,keyed bushing “E”, bushing “F”, and nut “G”,Figure 4.62 .

3. Remove bolt “M”, Figures 4.61 and 4.62 .

4. Remove gear “L”, keyed bushing “K”, bush-ing “J”, and nut “H”.

REASSEMBLY

- NOTE -The flats on nuts “G” and “H”, Figure4.62, fit into the relief slot on the backside of bracket “I”.

1. Slide keyed bushing “K”, Figure 4.62, ontobushing “J”.

2. Mount gear “L” onto keyed bushing “K”.

4-36 M-10C

Figure 4.61 - Gear Change BracketAssembly (English)

Tp4517.

Figure 4.62 - Gear Change BracketComponents (English)

Tp4518.

3. Slide bolt “M” through bushing “J” from the side opposite the large flat surface on bushing“J”.

4. Hold nut “H” inside the relief slot on the back side of bracket “I”.

5. Slide bolt “M” through bracket “I” from the front side and thread bolt “M” into nut “H”.

6. Slide keyed bushing “E” onto bushing “F”.

7. Mount gear “D”, spacer “C”, and gear “B” onto keyed bushing “E”.

8. Slide bolt “A” through bushing “F” from the side opposite the large flat surface on bushing“F”.

9. Hold nut “G” inside the relief slot on the back side of bracket “I”,

10. Slide bolt “A” through bracket “I” from the front side and thread bolt “A” into nut “G”.

GEAR CHANGE BRACKET (English-Metric)

DISASSEMBLY

1. Remove bolt “N”, Figures 4.63 and 4.64 .

2. Remove gear “O”, spacer “P”, gear “Q”, keyed bushing “R”, bushing “S”, and nut “T”, Fig-ure 4.64 .

3. Remove bolt “Z”, Figures 4.63 and 4.64 .

4. Remove gear “Y”, keyed bushing “X”, bushing “W”, and nut “U”, Figure 4.64 .

REASSEMBLY

- NOTE -The flats on nuts “N” and “Z”, Figure4.64, fit into the relief slot on the backside of bracket “V”.

1. Slide keyed bushing “X”, Figure 4.64, ontobushing “W”.

2. Mount gear “Y” onto keyed bushing “X”.

3. Slide bolt “Z” through bushing “W” from theside opposite the large flat surface on bush-ing “W”.

4. Hold nut “U” inside the relief slot on the backside of bracket “V”.

5. Slide bolt “Z” through bracket “V” from thefront side and thread bolt “Z” into nut “U”.

6. Slide keyed bushing “R” onto bushing “S”.

7. Mount gear “Q”, spacer “P”, and gear “O”onto keyed bushing “R”.

M-10C 4-37

Figure 4.63 - Gear Change BracketAssembly (English-Metric)

Tp4519.

8. Slide bolt “N” through bushing “S” from the side opposite the large flat surface on bushing“S”.

9. Hold nut “T” inside the relief slot on the back side of bracket “V”,

10. Slide bolt “N” through bracket “V” from the front side and thread bolt “N” into nut “T”.

GEAR CHANGE BRACKET LUBRICATION

- NOTE -This lubrication instruction applies to both the English and English-Metric gearchange brackets.

Lubricate the bushings and shafts on the gear change bracket with Mobil® Velocite® oil No. 6, asneeded.

If long run threading is involved, lubricate on a daily basis.

4-38 M-10C

Figure 4.64 - Gear Change BracketComponents (English)

Tp4520.

HEADSTOCK

REMOVAL

1. Remove the collet closer according to the procedure outlined on Page 4-1.

2. Remove three screws “A”, Figure 4.65, and collet closer mounting bracket “B”.

3. Remove snap ring “H” and remove handwheel “I”, Figure 4.5 .

4. Remove key “J”, washer “K” and washer “L”, Figure 4.6 .

5. On HLV®-H machines, remove the gearbox according to the appropriate procedure outlinedin this chapter.

On TFB®-H machines, remove four screws “C”, Figure 4.66, and cover “D”.

6. On HLV-H machines, place lever “G”, Figure 4.67, in the “Stop” position and lever “H” inthe center position.

On TFB-H machines, place lever “M”, Figure 4.68, in the “Brake” position and lever “N” inthe “Stop” position.

7. Pull “Start/Stop” pushbutton “L”, Figure 4.67, OUT to turn the machine ON.

8. On HLV-H machines, place lever “G” in “Low” range.

On TFB-H machines, place lever “M”, Figure 4.68, in “Forward” or “Reverse” and lever “N”in “Low” range.

9. Turn speed adjustment knob “K”, Figure 4.67, to “Slower” and hold in that position untilspindle speed stabilizes at 125 rpm.

M-10C 4-39

Figure 4.65 - Collet Closer MountingBracket Removal

Tp4521.

Figure 4.66 - Headstock Cover forTFB®-H Machine

Tp4522.

10. On HLV®-H machines, place lever “G” inthe “Stop” position to stop the spindle

On TFB®-H machines, place lever “M”, Fig-ure 4.68, in the “Brake” position and lever“N” in the “Stop” position.

11. Press “Start/Stop” pushbutton “L”, Figure4.67, IN to turn the machine OFF.

12. Open door “O”, Figure 4.69 .

13. Remove lock nut “P”, Figure 4.70 .

14. Raise the front of the motor mounting plateapproximately two inches and block it in thisposition, as shown in Figure 4.71 .

15. Roll motor belt “Q”, Figure 4.72, to the rightoff the pulley and let it rest on the pulleyhub, as shown.

16. Pull “Start/Stop” pushbutton “L”, Figure 4.67,OUT to turn the machine ON.

4-40 M-10C

Figure 4.67 - HLV-H Headstock Assembly

Tp4523.

Figure 4.68 - TFB-H Headstock Assembly

Tp4524.


Tp4525.


17. On HLV®-H machines, place lever “G” in “High” range.

On TFB®-H machines, place lever “M”, Figure 4.68, in “Forward” or “Reverse” and lever “N”in “High” range.

18. Turn speed adjustment knob “L”, Figure 4.67,to “Faster” and hold in that position until pul-ley hanger assembly “R”, Figure 4.72,reaches maximum upward travel.

19. On HLV-H machines, place lever “G”, Figure4.67, in the “Stop” position and allow thespindle motor to coast to a stop.

On TFB-H machines, place lever “N”, Figure4.68, in the “Stop” position and allow thespindle motor to coast to a stop.


21. Turn main disconnect switch “S”, Figure4.73, to the OFF position.

M-10C 4-41

Figure 4.70 - Drive Belt Adjustment Screw

Tp4526.

Figure 4.71 - Motor Mounting PlateBlocked in Position

Tp4527.


Tp4528.

22. Slide countershaft assembly “T”, Figure 4.74,to the extreme right and remove the spindlebelt over the left end of the countershaft.

23. Remove the cotter pin from the end of speedchange pull rod “U”, Figure 4.75, whichpasses through the headstock belt in the mo-tor compartment.

24. Move the spindle belt around the end of thepullrod.

25. Use a piece of wire as a hook to lift the spin-dle belt out of the pulley and out of the open-ing in the headstock.

26. Remove lock screw “Y”, Figure 4.76, andloosen the set screw under lock screw “Y”.

27. Loosen screw “Z”, Figure 4.77, in the motorcompartment to release the speed indicatorrod.

4-42 M-10C

Figure 4.73 - Main Disconnect Switch

Tp4529.

Figure 4.74 - Belt Removal OverCountershaft

Tp4530.


Tp4531.

- NOTE -It may be necessary to remove cablenut “E”, Figure 4.66, to remove vari-able speed control head “F”.

28. Lift variable speed control head “F”, Figure4.66, straight off.

29. Remove the speed indicator rod up throughthe headstock.

30. Remove six screws “I”, Figure 4.67, andname plate “J”.

31. Remove two screws “B”, Figure 4.78, andpull limit switch “C” out of the headstock togain access to the wire terminals on the limitswitch.

32. Tag the three wires connected to limit switch“C” for reconnection; then disconnect thewires.

33. Remove cable nut “W”, Figure 4.76, and pullthe limit switch wires out of the headstock.

34. Remove four bolts “X”.

35. Remove lock screw “V”.

36. Remove the set screw located under lock screw “V”.

37. Remove locking plug “E”, Figure 4.79 .

M-10C 4-43

Figure 4.76 - Back of Headstock

Tp4532.

Figure 4.77 - Indicator Rod Bracket

Tp4533.

Figure 4.78 - Spindle Lock Pin Limit Switch

Tp4534.

- CAUTION -DO NOT position the straps aroundeach end of the headstock spindle;damage to the spindle bearings mayresult.

38. Route lifting straps completely through theheadstock spindle.

39. Attach the lifting straps to a hoist.

- NOTE -Do not misplace the seal located underthe headstock.

40. Using a hoist and lifting straps carefully slidethe headstock OFF and UP with a smoothmotion.

REPLACEMENT

- CAUTION -DO NOT position the sling aroundthe machine spindle; damage to thespindle bearings may result.

1. Route lifting straps completely through theheadstock spindle.

2. Attach the lifting straps to a hoist and lift theheadstock.

3. Locate and remove any burrs on the ma-chine bed plate and dovetail areas where theheadstock is to be mounted; then, thoroughlyclean these areas.

4. Locate and remove any burrs on the bottomsurface and dovetail areas of the headstock;then, thoroughly clean these areas.

- NOTE -Applying the grease to the headstockseal will cause the seal to stay in placewhile the headstock is being mountedand also eliminates any shearing effecton the seal while the headstock is be-ing mounted.

5. Apply grease to the headstock seal; then, re-place the seal in the bottom of theheadstock.

4-44 M-10C

Figure 4.79 - Headstock Locking Plug

Tp4535.

Figure 4.80 - Headstock Locating Surfaces

Tp4536.

6. Carefully slide the headstock onto the bed plate with a smooth motion.

7. Position the headstock to locate machined surface “G”, Figure 4.80, of the headstock .008"[0.2 mm] forward (toward the tailstock end of the machine) of machined surface “F” on thebed casting.

- NOTE -Be sure the angle on locking plug “E”, Figure 4.79, matches the angle on the bedplate dovetail.

8. Replace locking plug “E”, Figure 4.79 .

9. Replace the set screw located under lock screw “V”, Figure 4.76 .

10. Replace and tighten lock screw “V”.

11. Replace and torque four bolts “X” to 65 lb-ft [88 Nm].

12. Reroute the spindle lock pin wires through the headstock and tighten cable nut “W”.

13. Connect the three limit switch wires to limit switch “C”, Figure 4.78 .

14. Mount limit switch “C” to the limit switch mounting plate using two screws “B”.

- NOTE -Clearance in the holes for screws “A” will allow the position of the limit switch to beadjusted to ensure that the limit switch works properly.

15. Move spindle lock pin “D” IN and OUT to be sure limit switch “C” is tripped when the spin-dle lock pin is pushed IN. Loosen screws “A” to reposition limit switch “C” as needed.

16. Mount name plate “J”, Figure 4.67, using six screws “I”.

17. Replace the indicator rod with the flat sidefacing toward the front of the machine.

18. Replace variable speed control head “F”, Fig-ure 4.66 .

19. Replace the set screw located under lockscrew “Y”, Figure 4.76 .

20. Replace lock screw “Y”.

21. Reposition the tip of the indicator rod at 3000rpm on the variable speed control head andtighten screw “Z”, Figure 4.77, in the motorcompartment.

- NOTE -When replacing the spindle belt, thegearbox shown in Figure 4.81, will notbe mounted. This allows for easierspindle belt replacement.

22. Cross the spindle belt, as shown in Figure4.81, feed it through opening “H”, Figure4.80, and down into the pedestal.

M-10C 4-45


Tp4537.

23. Use a piece of wire as a hook to lift the spindle belt into the spindle pulley.

24. Slide the spindle belt over the left end of countershaft assembly “T”, Figure 4.74, and ontothe left pulley of the countershaft assembly.

25. Remount the countershaft assembly by sliding the left end of the countershaft assemblyback into countershaft support bracket “R”, Figure 4.72 .

26. Reconnect pull rod “U”, Figure 4.75, and insert the cotter pin.

27. Remount the motor belt on the right side pulley.

28. Remove the block and carefully lower the front of the motor mounting plate.

29. Install lock nut “P”, Figure 4.70, but do not tighten.

30. Adjust belt tension according to the procedure outlined in “Adjusting Drive Belt Tension”,Page 3-2.

31. On HLV®-H machines, remount the gearbox according to the appropriate procedure out-lined in this chapter.

On TFB®-H machines, replace cover “D”, Figure 4.66, and four screws “C”.




35. Run the drive to both extremes of the speed range to be sure the speed indicator is ad-justed properly.

36. Check the headstock alignment as outlined in the next section, “Headstock Alignment”.

4-46 M-10C

HEADSTOCK ALIGNMENT

- NOTE -To properly check the headstock alignment, it will be necessary to contact theHardinge Service Department to obtain the use of a test arbor. When calling to ob-tain a test arbor, a Hardinge Telephone Service Technician will request specific in-formation, including the following:

Machine ModelMachine Serial Number

1. Thoroughly clean the spindle collet seat angle and check for burrs.

2. Install the test arbor in the headstock spindle.

3. Mount a .0001" [.002mm] indicator to a stable magnetic base holder on top of the toolholder slide.

Vertical Alignment

4. Locate the vertical centerline of the test arbor:

a) Position the indicator to touch the diameter of the test arbor at the outer end. Refer toFigure 4.82 .

b) Move the machine cross slide (X axis) to obtain the highest reading on the indicator.This will be the centerline of the test arbor.

5. Determine the center of the runout at the outer end of the test arbor:

a) Rotate the headstock spindle by hand and observe the total runout shown on the indica-tor.

b) Note the value at the midpoint of the indicator sweep.

c) Rotate the headstock spindle by hand until the indicator shows the value noted in step5b.

d) Without moving the indicator or rotating the headstock spindle, reset the indicator dial tozero (0).

6. Move the machine carriage (Z axis) toward the headstock six (6) inches [152.4 mm] to po-sition the indicator as shown in Figure 4.83 .

7. Observe the value shown on the indicator.

For vertical headstock alignment to be within specification, this observed value must fallwithin the following range:

0.0 « +.0005" [.012mm] (Outer end LOW)

8. If the vertical alignment is within specification, proceed to Horizontal Alignment, page 4-48.

If the vertical alignment is NOT within specification, proceed to step 9.

9. Move the machine carriage (Z axis) away from the headstock.

10. Remove the indicator and magnetic base from the top of the tool holder slide.

M-10C 4-47

11. Remove the test arbor from the headstockspindle.

12. Remove the headstock according to the pro-cedure beginning on page 4-39.

13. Locate and remove any burrs on the ma-chine bed plate and dovetail areas where theheadstock is to be mounted; then, thoroughlyclean these areas.

14. Locate and remove any burrs on the bottomsurface and dovetail areas of the headstock;then, thoroughly clean these areas.

15. Replace the headstock according to the pro-cedure beginning on page 4-44.

16. Install the test arbor in the headstock spin-dle.

17. Replace the indicator and magnetic base onthe top of the tool holder slide.


Horizontal Alignment

19. Position the indicator to touch the diameterof the test arbor at the outer end. Refer toFigure 4.84 .

20. Determine the center of the runout at theouter end of the test arbor:

a) Rotate the headstock spindle by hand andobserve the total runout shown on the in-dicator.

b) Note the value at the midpoint of the indi-cator sweep.

c) Rotate the headstock spindle by hand untilthe indicator shows the value noted in step 20b.

d) Without moving the indicator or rotating the headstock spindle, reset the indicator dial tozero (0).

21. Move the machine carriage (Z axis) toward the headstock six (6) inches [152.4 mm] to po-sition the indicator as shown in Figure 4.85 .


For horizontal alignment to be within specification, this observed value must fall within thefollowing range:

0.0 « -.0001" [.002mm] (Outer end FORWARD)

4-48 M-10C

Figure 4.82 - Vertical Alignment(Obtaining Value “A”)

Tp2223.

Figure 4.83 - Vertical Alignment(Obtaining Value “B”)

Ti2224.

23. If the horizontal alignment is within specifica-tion, the alignment procedure is complete.

If the vertical alignment is NOT within specifi-cation, proceed to step 24.

24. Move the machine carriage (Z axis) awayfrom the headstock to move the indicatoraway from the test arbor.

- NOTE -When loosened, four bolts “X”, Figure4.76, should still apply enough force onthe headstock to prevent it from mov-ing freely.

25. Slightly loosen four bolts “X”, Figure 4.76 .

26. Remove lock screw “V”.

27. Slightly loosen the set screw located underlock screw “V”.

- NOTE -It will be necessary to GENTLY tap onthe headstock to adjust the horizontalalignment.

28. Place a cloth over the area of the headstockto be tapped.

- CAUTION -Use a RUBBER or NYLON hammerto tap on the headstock. Damage tothe headstock surface may result ifanother type of hammer is used.

29. GENTLY tap on the headstock with aRUBBER or NYLON hammer to adjust thehorizontal alignment.

30. Tighten the set screw located under lock screw “V”, Figure 4.76 .

31. Replace and tighten lock screw “V”.

32. Torque four bolts “X” to 65 lb-ft [88 Nm].


M-10C 4-49

Figure 4.84 - Horizontal Alignment(Obtaining Value “C”)

Ti1974.

Figure 4.85 - Horizontal Alignment(Obtaining Value “D”)

Ti2222.

HEADSTOCK SPINDLE

Spindle Lock Pin

The electrical interlock between lock pin “D”, Figure 4.78, and the main drive motor is controlled bylimit switch “C”. The limit switch is located under name plate “J”, Figure 4.67, and is actuated by aplunger moved by lock pin “B”, Figure 4.78.

SPINDLE LOCK PIN LIMIT SWITCH REPLACEMENT

1. Turn main disconnect switch “S”, Figure 4.73, OFF.

2. Remove six screws “I”, Figure 4.67, and name plate “J”.

3. Remove two screws “B”, Figure 4.78, pull limit switch “C” out of the headstock to gain ac-cess to the wire terminals on the limit switch.

4. Tag the three wires connected to limit switch “C” for reconnection; then disconnect thewires.

5. Connect the three wires to the new limit switch.

6. Mount limit switch “C” to the limit switch mounting plate using two screws “B”.

- NOTE -Clearance in the holes for screws “A” will allow the position of the limit switch to beadjusted to ensure that the limit switch works properly.

7. Move spindle lock pin “D” IN and OUT to be sure limit switch “C” is tripped when the spin-dle lock pin is pushed IN. Loosen screws “A” to reposition limit switch “C” as needed.

8. Mount name plate “J”, Figure 4.67, using six screws “I”.

Lubrication

The headstock spindle is mounted on precision preloaded ball bearings. The preloading andresulting load-carrying capacity is engineered to take radial thrust, end thrust, or a combination ofboth.

The precision preloaded ball bearings are grease-packed for life and require no further lubrication.The entire bearing assembly is housed as a unit and is properly sealed to exclude dirt and foreignmatter. The spindle bearings are designed to operate at high speed with minimal friction or wear.

4-50 M-10C

- NOTES -

M-10C 4-51

- NOTES -

4-52 M-10C

CHAPTER 5 - ELECTRICAL

POWER CASE

ACCESSING THE POWER CASE

- WARNING -Be sure disconnect switch “H”, Fig-ure 5.2, is turned OFF before open-ing the power case door.

1. Press “Start/Stop” pushbutton “A”, Figure 5.1,or “Start/Stop” pushbutton “G”, Figure 5.8, INto turn the machine OFF.

2. Turn main disconnect switch “H”, Figure 5.2,to the OFF position.

3. Loosen two screws “I” and open the powercase door.

M-10C 5-1

Figure 5.1 - Variable Speed Control Box(HLV®-H Machine)

Tp4538.

Figure 5.2 - Power Case (External View)

Tp4539.

COMPONENT DESCRIPTION (HLV®-H Machine Power Case)

Refer to Figure 5.3 .

A - Terminal block #1 (1TB)

B - Autotransformer (2T)The autotranformer is used only on machines configured for the following voltages:

208V and 575V - 60Hz200V, 380V, and 415V - 50Hz

C - Disconnect switch (DISC.)

D - Fuses, main line (1FU)

E - Drum switch, speed range select (1DS)

F - Fuses, control transformer primary (2FU)

G - Control transformer (1T)

H - Terminal block #3 (3TB)

I - Fuse, optional worklight (5FU)

J - Fuse, power feed module (4FU)

K - Fuse, Control transformer secondary (3FU)

L - Main Contactor (4M)

M - Overload relay for coolant pump motor (OL1)

N - Overload relay for spindle motor (OL2)

O - Overload relay for speed change motor (OL3)

P - Terminal block #2 (2TB)

Q - Coolant pump motor contactor (5M)

R - Forward/Reverse contactor for spindle motor (3MF-3MR)

S - Forward/Reverse contactor for speed change motor (2MR-2ML)

T - Rectifier for speed change motor brake (RECT A)

5-2 M-10C

M-10C 5-3

Figure 5.3 - Power Case (Internal View)(HLV®-H Machines)

Tp4540.

COMPONENT DESCRIPTION (TFB®-H Machine Power Case)

Refer to Figure 5.4 .

A - Terminal block #1 (1TB)

B - Autotransformer (2T)The autotranformer is used only on machines configured for the following voltages:

208V and 575V - 60Hz200V, 380V, and 415V - 50Hz

C - Disconnect switch (DISC.)

D - Fuses, main line (1FU)

E - Drum switch, speed range select (1DS)

F - Fuses, control transformer primary (2FU)

G - Drum switch, forward/reverse/brake (2DS)

H - Control transformer (1T)

I - Fuse, optional worklight (5FU)

J - Fuse, power feed module (4FU)

K - Fuse, Control transformer secondary (3FU)

L - Main Contactor (4M)

M - Overload relay for coolant pump motor (OL1)

N - Overload relay for spindle motor (OL2)

O - Overload relay for speed change motor (OL3)

P - Terminal Block #2 (2TB)

Q - Coolant pump motor contactor (5M)

R - Forward/Reverse contactor for speed change motor (2MR-2ML)

S - Rectifier for speed change motor brake (RECT A)

5-4 M-10C

M-10C 5-5

Figure 5.4 - Power Case (Internal View)(TFB®-H Machines)

Tp4541.

POWER FEED CONTROL PANEL

- WARNING -Be sure disconnect switch “H”, Figure 5.2, is turned OFF before attemptingto service the power feed control panel.

1. Press “Start/Stop” pushbutton “A”, Figure 5.1, or “Start/Stop” pushbutton “G”, Figure 5.8, INto turn the machine OFF.

2. Turn main disconnect switch “H”, Figure 5.2, to the OFF position.

3. Remove six screws “T”, Figure 5.5.

4. Remove power feed control panel “U” from housing “V”.

POWER FEED MODULE

Power feed module “W”, Figure 5.6, serves two purposes:

The power feed module converts 110 volts A.C. to 90 volts pulsating D.C. for the powerfeed drive motor.

Through the use of potentiometer “A”, Figure 5.7, the power feed module controls SCR “X”,Figure 5.6, to vary the effective D.C. voltage level to the power feed drive motor, controllingthe motor speed.

5-6 M-10C

Figure 5.5 - Power Feed Control Panel(Front View)

Tp4542.

Figure 5.6 - Power Feed Module

Tp4543.

RESISTOR MODULE

Resistor module “C”, Figure 5.7, contains three 25 watt resistors and a 6 position terminal block.

Resistor “D” is a 47? 25 watt resistor used for dynamic braking of the power feed drive motor.

Resistor “E”, Figure 5.7, is a 1500? 25 watt resistor used as a load resistor for SCR “X”, Figure 5.6,on power feed module “W”.

Resistor “F”, Figure 5.7, is a 470? 25 watt resistor in series with the field windings in the powerfeed drive motor. This resistor reduces the voltage to the field windings, allowing higher motorspeeds.

SWITCHES

Potentiometer “A”, Figure 5.7, varies the effective D.C. voltage level to the power feed drive motorto control the motor speed.

Three position switch “B” controls the direction of travel for the power feed - left, right, or stop.

M-10C 5-7

Figure 5.7 - Resistor Module

Tp4544.

VARIABLE SPEED CONTROL PANEL

OPERATOR CONTROLS

Spindle Speed Adjustment

Switches “D”, Figure 5.1, and “H”, Figure 5.8, control spindle speed. These three-positionswitches are spring loaded and will return to the center position when released.

Turn the speed control switch to the desired position (“Faster” or “Slower”) and hold in this positionuntil the spindle reaches the desired speed.

Coolant

Switches “C”, Figure 5.1, and “I”, Figure 5.8, control the coolant.

In the ON position, coolant will flow whenever the machine is turned ON.

In the OFF position, coolant flow is disabled.

In the AUTO position, coolant will flow whenever the spindle is active.

- NOTES -On HLV®-H machines, lever “J”, Figure5.9, must be in the “Stop” position be-fore the machine can be turned ONwith switch “A”, Figure 5.1 .

On TFB®-H machines, lever “K”, Figure5.10, must be in the “Stop” position be-fore the machine can be turned ONwith switch “G”, Figure 5.8 .

Start/Stop Switch

When main disconnect switch “H”, Figure 5.2, isturned ON, pushbutton “A”, Figure 5.1, orpushbutton “G”, Figure 5.8, turns the machine ONwhen pulled OUT and turns the machine OFF whenpushed IN.

Spindle Brake (HLV-H Machines only)

Selector switch “B”, Figure 5.1, is a two-positionswitch that enables the spindle brake when set to the“BRAKE” position and disables the spindle brakewhen set to the “OFF” position.

5-8 M-10C

Figure 5.8 - Variable Speed Control Panel(TFB-H Machine)

Tp4545.

SWITCH REPLACEMENT

- WARNING -Be sure disconnect switch “H”, Figure 5.2, is turned OFF before attemptingto service the variable speed control panel.

1. Press “Start/Stop” pushbutton “A”, Figure 5.1, or “Start/Stop” pushbutton “G”, Figure 5.8, INto turn the machine OFF.

2. Turn main disconnect switch “H”, Figure 5.2, to the OFF position.

3. Remove eight screws “E”, Figure 5.1 .

4. Remove variable speed control panel “F” from control housing “G”.

5. Record the wiring connections on the faulty switch.

6. Disconnect the wiring connections on the faulty switch.

7. Remove the faulty switch.

- NOTE -The wiring diagram included in the machine documentation package contains com-plete machine wiring information.

8. Mount the replacement switch and reconnect the wiring as recorded in step 5.

9. Install variable speed control panel “F”, in control housing “G”, using eight screws “E”.

M-10C 5-9

Figure 5.9 - Headstock Levers(HLV®-H Machines)

Tp4546.

Figure 5.10 - Headstock Levers(TFB®-H Machines)

Tp4547.

- NOTES -

5-10 M-10C

CHAPTER 6 - MISCELLANEOUS

BED LEVERS (HLV®-H Machines)

REMOVAL

1. Remove the gear box according to the ap-propriate procedure:The procedure for removing the Englishgearbox begins on page 4-3.The procedure for removing the English-Met-ric gearbox begins on page 4-19.

2. Place lever “A”, Figure 6.1, in the “Stop” po-sition and lever “B” in the center position.

3. Turn coolant switch “G”, Figure 6.2, to theOFF position.

4. Pull “Start/Stop” pushbutton “E” OUT to turnthe machine ON.

5. Place lever “A”, Figure 6.1, in “Low” range.

6. Turn speed adjustment knob “F”, Figure 6.2,to “Slower” and hold in that position untilspindle speed stabilizes at 125 rpm.

7. Place lever “A”, Figure 6.1, in the “Stop” po-sition to stop the spindle

8. Press “Start/Stop” pushbutton “E”, Figure 6.2,IN to turn the machine OFF.


10. Remove lock nut “I”, Figure 6.4 .


12. Roll motor belt “J”, Figure 6.6, to the right offthe pulley and let it rest on the pulley hub, asshown.

13. Pull “Start/Stop” pushbutton “E”, Figure 6.2,OUT to turn the machine ON.

- WARNING -Stay clear of the spindle drive motorcompartment while the spindle mo-tor is running.

14. Place lever “A”, Figure 6.1, in “High” range.

M-10C 6-1

Figure 6.1 - Headstock Assembly(HLV-H Machines)

Tp4548.

Figure 6.2 - Variable Speed Control Box

Tp4549.

15. Turn speed adjustment knob “F”, Figure 6.2, to “Faster” and hold in that position until spin-dle speed stabilizes at 3000 rpm.

16. Place lever “A”, Figure 6.1, in the “Stop” position and allow the spindle motor to coast to astop.

17. Press “Start/Stop” pushbutton “E”, Figure 6.2, IN to turn the machine OFF.

18. Slide countershaft assembly “K”, Figure 6.7, to the extreme right and remove the spindlebelt over the left end of the countershaft.

6-2 M-10C


Tp4550.

Figure 6.4 - Drive Belt Adjusting Screw

Tp4551.

Figure 6.5 - Motor Mounting Plate Blockedin Position

Tp4552.


Tp4553.

19. Remove the cotter pin from the end of speed change pull rod “M”, Figure 6.8, whichpasses through the headstock belt in the motor compartment.

20. Use a piece of wire as a hook to lift the spindle belt out of the pulley and out of the open-ing in the headstock.

21. Remove lock screw “N”, Figure 6.9, and loosen the set screw under lock screw “N”.

22. Loosen screw “R”, Figure 6.10, located in the motor compartment, to release the speed in-dicator rod.

- NOTE -It may be necessary to remove conduitnut “S”, Figure 6.11, to remove vari-able speed control head “T”.

23. Lift variable speed control head “T”, Figure6.11, straight off.

24. Remove the speed indicator rod by lifting itup through the headstock.

25. Remove six screws “C”, Figure 6.1, andname plate “D”.

26. Remove two screws “U”, Figure 6.12, pulllimit switch “W” out of the headstock to gainaccess to the wire terminals on the limitswitch.

27. Tag the three wires connected to limit switch“W” for reconnection; then, disconnect thewires.

M-10C 6-3

Figure 6.7 - Belt Removal OverCountershaft

Tp4554.


Tp4555.

Figure 6.9 - Back of Headstock

Tp4556.

28. Remove cable nut “Q”, Figure 6.9, and pull the wires out of the headstock.

29. Remove four bolts “O”.

30. Remove lock screw “P”.

31. Remove the set screw located under lock screw “P”.

32. Remove locking plug “Y”, Figure 6.13 .

33. Slide the headstock toward the tailstock to reveal the opening in the bed.

34. Loosen lock nut “B”, Figure 6.14 .

6-4 M-10C

Figure 6.10 - Indicator Rod Bracket

Tp4557.

Figure 6.11 - Control Head Conduit Nut

Tp4558.

Figure 6.12 - Spindle Lock Pin Limit Switch

Tp4559.

Figure 6.13 - Headstock Locking Plug

Tp4560.

35. Remove taper pin “D”, Figure 6.15, from the positive stop.

36. Unscrew stop rod “C”, Figure 6.14, from stop rod extension “A”.

- NOTE -Some of the remaining steps in this procedure will refer to the illustration in Figure6.16, as well as the appropriate photograph(s).

M-10C 6-5

Figure 6.14 - Stop Rod

Tp4561.

Figure 6.15 - Stop Rod Positive Stop

Tp4562.

Figure 6.16 - Sectioned View of Bed Assembly(HLV®-H Machines)

Ti2237.EFG N

O

P

Q RS T S

VM

W

- NOTE -Nut “F”, Figures 6.16 and 6.17, is accessible through the opening in the bed.

37. Loosen nut “F”, Figures 6.16 and 6.17 .

38. Remove screw “E” and block “G”.

39. Remove lock screw “H”, Figure 6.18, set screw “I”, spring “J”, and plunger “K”.

40. Remove stop rod extension “L”, Figure 6.19 .

6-6 M-10C

Figure 6.17 - Reverse Lever Shaft

Tp4563.

Figure 6.18 - Stop Rod Plunger AssemblyTp4564.

Figure 6.19 - Stop Rod Extension Removal

Tp4565.

Figure 6.20 - Speed Lever Shaft

Tp4566.

- NOTE -Taper pin “M”, Figures 6.16 and 6.20, can be accessed through the spindle drivemotor compartment

41. Using a hammer and punch, remove taper pin “M”, Figures 6.16 and 6.20, from the lowershaft to free speed range lever “N”.

42. Remove nut “O”, Figures 6.16 and 6.21, washer, and spring washer.

43. Hold speed range lever “N”, Figures 6.16 and 6.20, and remove shaft assembly “V”, Figure6.16, from the bed assembly.

- NOTE -Taper pin “Q”, Figures 6.16 and 6.22, can be accessed through the spindle drivemotor compartment

44. Using a hammer and punch, remove taper pin “Q”, Figures 6.16 and 6.22, from the uppershaft to free reverse lever “R”.

(continued on next page)

M-10C 6-7

Figure 6.21 - Rear View of Bed Levers

Tp4567.


Tp4568.

- NOTE -Taper pin “S”, Figures 6.16 and 6.23,can be accessed through the spindledrive motor compartment.

45. Rotate the upper lever shaft to point thesmall end of taper pin “S”, Figures 6.16 and6.23, down toward the spindle drive motorcompartment

46. Using a hammer and punch, remove taperpin “S” from the upper shaft to free stop rodlever “T”.

47. Remove nut “P”, Figures 6.16 and 6.21,washer, and spring washer.

48. Hold the reverse lever and stop rod lever inposition and remove shaft assembly “W”,Figure 6.16, from the bed assembly.

6-8 M-10C


Tp4569.

REPLACEMENT

- NOTE -Some of the steps in this procedure will refer to the illustration in Figure 6.16, aswell as the appropriate photograph(s).

1. Position block “U”, Figure 6.24, in the reverse lever with the chamfered end of the hole ori-ented as shown.

2. Hold reverse lever “R” and stop rod lever “T”, Figure 6.16, in position and slide shaft as-sembly “W” into the bed assembly.

3. Replace spring washer, washer, and nut “P”, Figures 6.16 and 6.21 .

4. Align the hole in reverse lever “R”, Figures 6.16 and 6.22, with the appropriate hole in theshaft assembly “W”, Figure 6.16 .

5. Replace taper pin “Q”, Figures 6.16 and 6.22 .

6. Align the hole in stop rod lever “T”, Figures 6.16 and 6.23, with the appropriate hole inshaft assembly “W”, Figure 6.16 .

7. Replace taper pin “S”.

8. Hold speed lever “N”, Figures 6.16 and 6.20, in position and replace shaft assembly “V”,Figure 6.16 .

9. Replace spring washer, washer, and nut “O”, Figures 6.16 and 6.21 .

10. Align the hole in speed lever “N”, Figures 6.16 and 6.20, with the hole in shaft “V”, Figure6.16 .

11. Replace taper pin “M”, Figures 6.16 and 6.20 .

12. Replace stop rod extension “L”, Figure 6.19 .

13. Replace screw “E” and block “G”, Figures6.16 and 6.17 .

14. Tighten nut “F”.

15. Thread stop rod “C”, Figure 6.14, into stoprod extension “A”, but do not tighten.

16. Position the positive stop and replace taperpin “D”, Figure 6.15 .

17. Tighten stop rod “C” in stop rod extension“A”; then, tighten lock nut “B”, Figure 6.14 .

18. Replace plunger “K”, Figure 6.18, spring “J”,and set screw “I”.

19. Adjust set screw “I”, Figure 6.18, to obtainthe desired amount of detent on lever “B”,Figure 6.1 .

20. Replace and tighten lock screw “H”, Figure6.18 .

M-10C 6-9

Figure 6.24 - Reverse Lever

Tp4570.

21. Position the headstock to locate machinedsurface “Y”, Figure 6.25, of the headstock.008" [0.2 mm] forward (toward the tailstockend of the machine) of machined surface “Z”on the bed casting.

22. Replace locking plug “Y”, Figure 6.13 .

23. Replace the set screw located under lockingscrew “P”, Figure 6.9 .

24. Replace and tighten lock screw “P”.

25. Replace and torque four bolts “O” to 65 lb-ft[88 Nm].

26. Reroute the spindle lock pin wires throughthe headstock and tighten cable nut “Q”.

27. Connect the three limit switch wires to limitswitch “W”, Figure 6.12 .

28. Mount limit switch “W” to the limit switchmounting plate using two screws “U”.

- NOTE -Clearance in the holes for screws “V”will allow the position of the limit switchto be adjusted to ensure that the limitswitch works properly.

29. Move spindle lock pin “X” IN and OUT to be sure limit switch “W” is tripped when the spin-dle lock pin is pushed IN. Loosen two screws “V” to reposition limit switch “W” as needed.Tighten screws “V” to secure the setting.

30. Mount name plate “D”, Figure 6.1, using six screws “C”.

31. Replace the spindle speed indicator rod with the flat side facing toward the front of the ma-chine.

32. Replace variable speed control head “T”, Figure 6.11 .

33. If it was necessary to remove conduit nut “S”, Figure 6.11, to remove variable speed con-trol head “T”, replace conduit nut “S” at this time.

34. Replace the set screw located under lock screw “N”, Figure 6.9 .

35. Replace lock screw “N”.

36. Reposition the tip of the spindle speed indicator rod at 3000 rpm on the variable speedcontrol box and tighten screw “R”, Figure 6.10, in the motor compartment.

- NOTE -When replacing the spindle belt, the gearbox shown in Figure 6.26 will not bemounted. This allows for easier spindle belt replacement.

37. Cross the spindle belt, as shown in Figure 6.26, and feed it through opening “X”, Figure6.25, and down into the pedestal.

6-10 M-10C

Figure 6.25 - Headstock Locating Surfaces

Tp4571.

38. Use a piece of wire as a hook to lift the spin-dle belt onto the spindle pulley.

39. Slide the spindle belt over the end ofcountershaft assembly “K”, Figure 6.7, andonto the left pulley of the countershaft as-sembly.

40. Remount the countershaft assembly by slid-ing the left end of the countershaft assemblyback into countershaft support bracket “L”.

41. Reconnect pullrod “M”, Figure 6.8, and insertthe cotter pin.

42. Remount the motor belt on the right side pul-ley of the countershaft assembly.

43. Remove the block and carefully lower thefront of the motor mounting plate.

44. Install lock nut “I”, Figure 6.4, but do nottighten.

45. Check belt tension according to the proce-dure outlined in “Checking Drive Belt Ten-sion”, Page 3-1.

46. If necessary, adjust belt tension according to the procedure outlined in “Adjusting Drive BeltTension”, Page 3-2.

47. Remount the gearbox according to the appropriate procedure:

The procedure for remounting the English gearbox begins on page 4-16.

The procedure for remounting the English-Metric gearbox begins on page 4-35.


49. Check the headstock alignment according to the procedure outlined in “Headstock Align-ment”, beginning on page 4-47.

M-10C 6-11


Tp4572.

BED LEVERS (TFB®-H Machines)

REMOVAL

1. Remove and clean the collet closer according to the procedure outlined on page 4-1.

2. Remove snap ring “A”, Figure 6.27, and remove handwheel “B”.

3. Remove key “C”, Figure 6.28, washer “D”, and washer “E”.

4. Remove four screws “F”, Figure 6.29, and cover “G”.

5. Place lever “H”, Figure 6.30, in the “Brake” position and lever “I” in the “Stop” position.

6. Turn coolant switch “N”, Figure 6.31, to the OFF position.


8. Place lever “H”, Figure 6.30, in the “Forward”or “Reverse” position and lever “I” in the“Low” position.

9. Turn speed adjustment knob “M”, Figure6.31, to “Slower” and hold in that position un-til spindle speed stabilizes at 125 rpm.

10. Place lever “H”, Figure 6.30, in the “Brake”position and lever “I” in the “Stop” position.



13. Remove lock nut “I”, Figure 6.4 .


15. Roll motor belt “J”, Figure 6.6, to the right offthe pulley and let it rest on the pulley hub, asshown.


- WARNING -Stay clear of the spindle drive motorcompartment while the spindle mo-tor is running.

17. Place lever “H”, Figure 6.30, in the “Forward”or “Reverse” position and lever “I” in the“High” position.

6-12 M-10C

Figure 6.27 - Spindle Handwheel

Tp4573.

Figure 6.28 - Handwheel Key and Washers

Tp4574.

18. Turn speed adjustment knob “M”, Figure 6.31, to “Faster” and hold in that position untilspindle speed stabilizes at 3000 rpm.

19. Place lever “H”, Figure 6.30, in the “Brake” position and lever “I” in the “Stop” position.

20. Press “Start/Stop” pushbutton “L”, Figure 6.31, IN to turn the machine OFF.

21. Slide countershaft assembly “K”, Figure 6.7, to the extreme right and remove the spindlebelt over the left end of the countershaft.

22. Remove the cotter pin from the end of speedchange pull rod “M”, Figure 6.8, whichpasses through the headstock belt in the mo-tor compartment.

23. Use a piece of wire as a hook to lift the spin-dle belt out of the pulley and out of the open-ing in the headstock.

24. Remove lock screw “N”, Figure 6.9, andloosen the set screw under lock screw “N”.

25. Loosen screw “R”, Figure 6.10, located in themotor compartment, to release the speed in-dicator rod.

- NOTE -It may be necessary to remove cablenut “S”, Figure 6.11, to remove vari-able speed control head “T”.

26. Lift variable speed control head “T”, Figure6.11, straight off.

M-10C 6-13

Figure 6.29 - Headstock Cover(TFB®-H Machines)

Tp4575.

Figure 6.30 - Headstock Assembly(TFB-H Machines)

Tp4576.

Figure 6.31 - Variable Speed Control Box(TFB-H Machines)

Tp4577.

27. Remove the speed indicator rod by lifting it up through the headstock.

28. Remove six screws “J”, Figure 6.30, and name plate “K”.

29. Remove two screws “U”, Figure 6.12, pull limit switch “W” out of the headstock to gain ac-cess to the wire terminals on the limit switch.

30. Tag the three wires connected to limit switch “W” for reconnection; then disconnect thewires.

31. Remove cable nut “Q”, Figure 6.9, and pull the wires out of the headstock.

32. Remove four bolts “O”.

33. Remove lock screw “P”.

34. Remove the set screw located under lock screw “P”.

35. Remove locking plug “Y”, Figure 6.13 .

36. Slide the headstock toward the tailstock to reveal the opening in the bed.

- NOTE -Taper pin “U”, Figure 6.32, can be accessed through the spindle drive motor com-partment

37. Using a hammer and punch, remove taper pin “U”, Figure 6.32, from the lower shaft to freethe reverse lever.

38. Remove nut “O”, Figures 6.21 and 6.32, washer, and spring washer.

39. Hold reverse lever “T”, Figure 6.32, and remove shaft assembly “V”.

- NOTE -Taper pin “R” can be accessed through the spindle drive motor compartment.

40. Using a hammer and punch, remove taper pin “R” from the upper shaft to free speed lever“Q”.

41. Remove nut “P”, Figure 6.21 and 6.32, washer, and spring washer.

42. Hold speed lever “Q”, Figure 6.32, and remove shaft assembly “S”.

6-14 M-10C

REPLACEMENT

- NOTE -Some of the steps in this procedure will refer to the illustration in Figure 6.32, aswell as the appropriate photograph(s).

1. Hold speed lever “Q”, Figure 6.32, in position and slide shaft assembly “S” into the bed as-sembly.

2. Replace spring washer, washer, and nut “P”, Figures 6.21 and 6.32 .

3. Align the hole in speed lever “Q”, Figure 6.32, with the hole in the shaft assembly “S”.

4. Replace taper pin “R”.

5. Hold speed lever “T” in position and replace shaft assembly “V”.

6. Align the hole in speed lever “T” with the hole in the shaft assembly “V”.

7. Replace taper pin “U”.

8. Replace spring washer, washer, and nut “O”, Figures 6.21 and 6.32 .

9. Position the headstock to locate machined surface “Y”, Figure 6.25, of the headstock .008"[0.2 mm] forward (toward the tailstock end of the machine) of machined surface “Z” on thebed casting.

10. Replace locking plug “Y”, Figure 6.13 .

11. Replace the set screw located under locking screw “P”, Figure 6.9 .

12. Replace and tighten lock screw “P”.

M-10C 6-15

Figure 6.32 - Sectioned View of Bed Assembly(TFB®-H Machines)

S R Q

P

O

T U V Ti2251.

13. Replace and torque four bolts “O” to 65 lb-ft [88 Nm].

14. Reroute the spindle lock pin wires through the headstock and tighten cable nut “Q”.

15. Connect the three limit switch wires to limit switch “W”, Figure 6.12 .

16. Mount limit switch “W” to the limit switch mounting plate using two screws “U”.

- NOTE -Clearance in the holes for screws “V” will allow the position of the limit switch to beadjusted to ensure that the limit switch works properly.

17. Move spindle lock pin “X” IN and OUT to be sure limit switch “W” is tripped when the spin-dle lock pin is pushed IN. Loosen two screws “V” to reposition limit switch “W” as needed.Tighten screws “V” to secure the setting.

18. Mount name plate “K”, Figure 6.30, using six screws “J”.

19. Replace the spindle speed indicator rod with the flat side facing toward the front of the ma-chine.

20. Replace variable speed control head “T”, Figure 6.11 .

21. If it was necessary to remove conduit nut “S” to remove variable speed control head “T”,replace conduit nut “S” at this time.

22. Replace the set screw located under lock screw “N”, Figure 6.9 .

23. Replace lock screw “N”.

24. Reposition the tip of the spindle speed indicator rod at 3000 rpm on the variable speedcontrol box and tighten screw “R”, Figure 6.10, in the motor compartment.

- NOTE -When replacing the spindle belt, the cover shown in Figure 6.26 will not bemounted. This allows for easier spindle belt replacement.

25. Cross the spindle belt, as shown in Figure 6.26, and feed it through opening “X”, Figure6.25, and down into the pedestal.

26. Use a piece of wire as a hook to lift the spindle belt onto the spindle pulley.

27. Slide the spindle belt over the end of countershaft assembly “K”, Figure 6.7, and onto theleft pulley of the countershaft assembly.

28. Remount the countershaft assembly by sliding the left end of the countershaft assemblyback into countershaft support bracket “L”.

29. Reconnect pullrod “M”, Figure 6.8, and insert the cotter pin.

30. Remount the motor belt on the right side pulley of the countershaft assembly.

31. Remove the block and carefully lower the front of the motor mounting plate.

32. Install lock nut “I”, Figure 6.4, but do not tighten.

33. Check belt tension according to the procedure outlined in “Checking Drive Belt Tension”,Page 3-1.

6-16 M-10C

34. If necessary, adjust belt tension according to the procedure outlined in “Adjusting Drive BeltTension”, Page 3-2.

35. Replace cover “G”, Figure 6.29, and four screws “F”.


37. Check the headstock alignment according to the procedure outlined in “Headstock Align-ment”, beginning on page 4-47.

M-10C 6-17

COOLANT FACILITIES

Clean the machine oil sump regularly, depending on the type of material being machined.

- CAUTION -Use petroleum based cutting fluids only. If water based coolants are used,the machine warranty will be voided.

TO CLEAN THE SUMP

1. Press “Start/Stop” pushbutton “E”, Figure .2, IN to turn the machine OFF.

2. At the back of the machine, place a drain pan capable of holding at least 3 gallons of liquidunder drain plug “W”, Figure 6.33 .

3. Remove drain plug “W” and allow the coolant sump to drain into the drain pan.

4. Remove four screws “X”, Figure 6.34, and remove sump cover “Y”.

- WARNING -DO NOT remove chips by hand. Use a small shovel or similar device for chipremoval.

5. Remove any chips present in the coolant sump.

6. Clean the coolant sump and sump cover with mineral spirits.

7. Replace sump cover “Y” and screws “X”, Figure 6.34, and drain plug “W”, Figure 6.33 .

8. Remove the drain pan and properly dispose of the used coolant.

9. Refill the coolant sump with three gallons of fresh coolant.

COOLANT PUMP MOTOR LUBRICATION

The coolant pump motor bearings are grease packed for life and require no further lubrication.

6-18 M-10C

Figure 6.33 - Coolant Drain Plug

Tp4578.

Figure 6.34 - Coolant Sump Cover

Tp4579.

TAILSTOCK

- NOTE -Return the tailstock assembly to thefactory for repairs involving thetailstock body, spindle, or gib.

TAILSTOCK DISASSEMBLY

- WARNING -The tailstock assembly weighs ap-proximately 60 lb [27.2 kg].

- NOTE -Tailstock locking lever “A”, Figure 6.35,is shown in the locked position.

1. Loosen tailstock locking lever “A”, Figure6.35, and remove the tailstock over the endof the bed.

2. Disassemble the tailstock spindle and feedscrew:

a) Remove nut “C”, Figure 6.36, and thewasher.

b) Remove handwheel “D” and dial “E”, Fig-ure 6.37, from the tailstock feed screw.

c) Remove dial “E” from handwheel “D”.

- WARNING -Plug “F”, Figure 6.38, isspring-loaded. Exercise care whenremoving plug “F” from thehandwheel.

d) Remove plug “F” and spring “G”, Figure6.38, from the handwheel.

- NOTE -Do not misplace the plug located underscrew “H”, Figure 6.39 .

e) Loosen screw “H” and remove zero ring“I”, Figure 6.39 .

f) Remove four screws “J” and end cap “K”,Figure 6.40, from the tailstock body.

g) Remove key “L”.

M-10C 6-19

Figure 6.35 - Tailstock Locking Lever

Tp4580.

Figure 6.36 - Tailstock Handwheel Locknut

Tp4581.

Figure 6.37 - Tailstock HandwheelRemoval

Tp4582.

h) Remove screw “M”, Figure 6.41 .

i ) Remove spindle key “N”, Figure 6.42, us-ing one screw “J”, Figure 6.40 .

- CAUTION -Extreme care should be exercisedduring steps “j”, “k”, and “l” to pre-vent damage to the precision sur-faces of the spindle diameters andthe tailstock body bore.

j) Remove tailstock spindle “O”, Figure 6.43.

k) Remove feed screw “P”, Figure 6.44 .

l) Remove bearing “Q”, Figure 6.45 .

m) Remove nut “R”, half nut “S”, screw “T”,and half nut “U” from tailstock spindle “O”,Figure 6.46 .

6-20 M-10C

Figure 6.38 - Plug and Spring for Dial

Tp4583.

Figure 6.39 - Tailstock Zero Ring

Tp4584.

Figure 6.40 - Tailstock End Cap

Tp4585.

Figure 6.41 - Lockscrew for TailstockSpindle Key

Tp4586.

Figure 6.42 - Tailstock Spindle KeyRemoval

Tp4587.

3. Rotate spindle locking lever “A”, Figure 6.47, counterclockwise to remove shim “B”, andbinding nut sections “C” and “D”.

4. Remove tailstock locking lever “E”, Figure 6.48, and components:

a) Remove screw “F”, washer “G”, lever “E”, and spacer “H”.

b) Unscrew clamp bolt “I”.

c) Unscrew locking plug “J”.

M-10C 6-21

Figure 6.43 - Tailstock Spindle

Tp4588.

Figure 6.44 - Tailstock Feed Screw

Tp4589.

Figure 6.45 - Feed Screw Bearing Figure 6.46 - Adjustable Feed Screw Nut

Tp4591.Tp4590.

6-22 M-10C

Figure 6.47 - Tailstock Spindle Lock andComponents

Tp4592.

Figure 6.48 - Bed Locking Lever and Components

Tp4593.

TAILSTOCK REASSEMBLY

1. Reassemble the tailstock spindle and feed screw:

a) Replace half nut “U” and screw “T”, Figure 6.46 .

b) Install half nut “S” in spindle “O”, leaving a sufficient projection to mount lock nut “R”.

c) Install lock nut “R” on half nut “S”, but do not tighten.

d) Thread feed screw “P”, Figure 6.44, into half nut “S”, Figure 6.46, slowly while turninghalf nut “S” gradually until the threads in half nut “S” line up with the threads in half nut“U”, allowing the feed screw to thread into half nut “U”.

e) Turn half nut “S”, Figure 6.46, inward until a slight backlash is encountered when feedscrew “P”, Figure 6.44, is turned.

- NOTE -When the tailstock is assembled, there should be a maximum backlash of threegraduations on the handwheel dial.

f) Hold half nut “S” and tighten nut “R”, Figure 6.46 .

g) Hold half nut “S” and nut “R”, Figure 6.46, and remove feed screw “P”, Figure 6.44 .

- CAUTION -Extreme care should be exercised during steps “h” and “k” to prevent dam-age to the precision surfaces of the spindle diameters and the tailstock bodybore.

h) Replace bearing “Q”, Figure 6.45, in the tailstock body.

i) Lubricate feed screw “P”, Figure 6.44, with Cosmolube No. 2 grease.

j) Lubricate spindle “O”, Figure 6.43, with Mobil Velocite Oil No. 6.

k) Replace feed screw “P”, Figure 6.44, and spindle “O”, Figure 6.43, in the tailstock body.

- NOTE -Use one screw “J”, Figure 6.40, to replace spindle key “N”, Figure 6.42 .

l) Line up the keyway in the spindle and replace spindle key “N”, Figure 6.42 .

m) Replace screw “M”, Figure 6.41 .

- NOTE -Tighten screws “J”, Figure 6.40, alternately and evenly.

n) Replace end cap “K” using four screws “J”, Figure 6.40 .

o) Replace key “L”.

- NOTE -Be sure the nylon plug is under screw “H”, Figure 6.39 .

p) Replace zero ring “I”, Figure 6.39, but do not tighten screw “H”.

q) Replace spring “G” and plug “F”, Figure 6.38 .

M-10C 6-23

r) Replace dial “E” on handwheel “D”, Figure 6.37 .

s) Mount handwheel “D”, Figure 6.37, on the feed screw, as shown in Figure 6.36 .

t) Replace the washer and nut “C”, Figure 6.36 .

u) Set the clearance between dial “E”, Figure 6.37, and zero ring “I”, Figure 6.39, at .002"[.05 mm] to .004" [.1 mm].

v) Tighten screw “H”, Figure 6.39 .

2. Replace spindle locking lever “A”, Figure 6.47, and components:

- CAUTION -The angled flats on binding nut sections “C” and “D” must be placed againstthe tailstock spindle or serious scoring of the spindle will result.

- NOTE -Binding nut sections “C” and “D” should be flush with the tailstock casting whenthey are properly positioned.

a) Replace binding nut sections “C” and “D”.

b) Replace shim “B” on lever “A”.

c) Insert lever “A” through bushing “C” and the tailstock body; then, thread it into bindingnut “D”.

3. Replace tailstock locking lever “E”, Figure 6.48, and components:

a) Replace the tailstock on the machine bed.

b) Thread locking plug “J” into clamp bolt “I” until a gap of approximately 13/32 of an inch[10.3 mm] exists between the square shoulder on locking plug “J” and clamp bolt “I”.

c) Thread clamp bolt “I” into the tailstock body.

d) Replace spacer “H”.

e) Replace lever “E” and turn it clockwise until locking plug “J” contacts the bed plate.

f) Remove lever “E” and reorient it on the splined shaft so that 150 lb-in [17 Nm] of torqueis required to locate lever “E” against stop pin “K”.

g) Replace washer “G” and screw “F”.

6-24 M-10C

TAILSTOCK ALIGNMENT

- NOTE -To properly check the tailstock alignment, it will be necessary to contact theHardinge Service Department to obtain the use of a test arbor. When calling to ob-tain a test arbor, a Hardinge Telephone Service Technician will request specific in-formation, including the following:

Machine ModelMachine Serial Number

If tailstock misalignment is suspected, perform the following:

1. Check the tapered shank of the tailstock center being used. Burrs on the tapered shankwill not allow the tailstock center to seat evenly.

2. Check the spindle taper of the tailstock for burrs. If necessary, hand ream the tailstockspindle taper VERY LIGHTLY to remove the burrs. (#2 Morse taper)

3. Remove the tailstock from the bed and:

a) Check for chip buildup between the tailstock and the bed plate.

b) Check for burrs on the tailstock dovetail area and the dovetail on the bed plate.

4. Clean tailstock dovetail area and the dovetail on the bed plate with mineral spirits.

5. Replace the tailstock on the machine bed.

6. Install the tailstock dead center in the tailstock spindle.

7. On the headstock, thoroughly clean the spindle collet seat angle with mineral spirits andcheck for burrs.

8. Install a dead center in the headstock spindle.

9. Using handwheel “D”, Figure 6.36, extend the tailstock spindle 3-1/2 inches [88.9 mm].

10. Holding the test arbor between the headstock and spindle centers, slide the tailstock to-ward the headstock until the test arbor is barely held in position by the two centers.

- NOTE -When locking the tailstock assembly in position for the alignment checks, lockinglever “A”, Figure 6.35, should be tightened to 150 lb-in [17 Nm].

11. Lock the tailstock in position using bed locking lever “A”, Figure 6.35 .

- NOTE -The pressure applied against the test arbor should be sufficient to firmly hold thetest arbor in place, yet allow it to be rotated by hand.

12. Use tailstock handwheel “D”, Figure 6.36, to apply pressure against the test arbor.

13. Lock the tailstock spindle in position by turning locking handle “B”, Figure 6.35, clockwise.

14. Mount a .0001" [.002mm] indicator to a stable magnetic base holder on top of the toolholder slide.

M-10C 6-25

Horizontal Alignment

- NOTE -If there are any problems with the horizontal alignment that are not due to thepresence of burrs, chips, or other foreign material, it will be necessary to contactthe Hardinge Service Department.

15. Position the indicator to touch the diameter of the test arbor at the headstock end as closeto the arbor centerline as possible. Refer to Figure 6.49 .

16. Determine the center of the runout at the headstock end of the test arbor:

a) Rotate the test arbor and observe the total runout shown on the indicator.


c) Rotate the test arbor until the indicator shows the value noted in step 16b.

d) Without moving the indicator or turning the test arbor, reset the indicator dial to zero (0).

17. Move the machine carriage (Z axis) toward the tailstock a distance of six (6) inches [152.4mm] to position the indicator as shown in Figure 6.50 .


For the horizontal tailstock alignment to be within specification, this observed value mustfall within the following range on the indicator dial:

0.0 ↔ +0.0001 inches [.0025 mm] (Tailstock end FORWARD)

19. If the horizontal alignment is within specification, proceed to Vertical Alignment.

If the horizontal alignment is NOT within specification, check for chip buildup or burrs, asdescribed in the beginning of this procedure; then, recheck the horizontal alignment of thetailstock.

6-26 M-10C

Figure 6.49 - Horizontal Alignment(Headstock End of Arbor)

Ti2270.

Figure 6.50 - Horizontal Alignment(Tailstock End of Arbor)

Ti2269.

Vertical Alignment

20. Position the indicator to touch the diameter of the test arbor at the headstock end as closeto the arbor centerline as possible. Refer to Figure 6.51 .

21. Determine the center of the runout at the headstock end of the test arbor:

a) Rotate the test arbor and observe the total runout shown on the indicator.


c) Rotate the test arbor until the indicator shows the value noted in step 21b.

d) Without moving the indicator or turning the test arbor, reset the indicator dial to zero (0).

22. Move the machine carriage (Z axis) toward the tailstock a distance of six (6) inches [152.4mm] to position the indicator as shown in Figure 6.52 .


24. For the vertical tailstock alignment to be within specification, this observed value must fallwithin the following range on the indicator dial:

+.0005 inches [.013mm] ↔ +.001 inches [.025mm] (Tailstock end HIGH)

If the vertical alignment is within specification, the alignment procedure is complete.

If the vertical alignment is NOT within specification, check for chip buildup or burrs, as de-scribed in the beginning of this procedure; then, recheck the horizontal and vertical align-ment of the tailstock.

M-10C 6-27

Figure 6.51 - Vertical Alignment(Headstock End of Arbor)

Ti2272.

Figure 6.52 - Vertical Alignment(Tailstock End of Arbor)

Ti2271.

PREVENTIVE MAINTENANCE SCHEDULE

DAILYPage

Run the drive through the entire speed range . . . . . . . . . . 3-22

Operate the carriage lubricator . . . . . . . . . . . . . . . . . 1-33

Lubricate the threading change gear bracket . . . . . . . . . . 4-38

WEEKLYClean and lubricate the carriage gear rack . . . . . . . . . . . 1-15

Clean and lubricate the carriage lead screw. . . . . . . . . . . 1-21

Clean and lubricate the carriage lead screw nut . . . . . . . . . 1-26

Remove, clean, and lubricate the collet closer. . . . . . . . . . 4-1

MONTHLYCheck spindle and motor belt tension. . . . . . . . . . . . . . 3-1

Lubricate the variable speed drive . . . . . . . . . . . . . . . 3-22

Clean and lubricate the tool post slide . . . . . . . . . . . . . 2-12

Clean and lubricate the cross feed screw and feed screw nut . . 2-4

BI-MONTHLYChange the oil in the carriage apron:Removing the used oil . . . . . . . . . . . . . . . . . . . . . 1-1Adding the new oil . . . . . . . . . . . . . . . . . . . . . . 1-9

QUARTERLYLubricate the gear box:English gear box . . . . . . . . . . . . . . . . . . . . . . . 4-2,English-Metric gearbox . . . . . . . . . . . . . . . . . . . . 4-18

Lubricate the drive countershaft . . . . . . . . . . . . . . . . 3-22

DEPENDING ON USEKeep the carriage oil reservoir full . . . . . . . . . . . . . . . 1-33

Keep oil in the sight window of the carriage apron. . . . . . . . 1-9

Clean the coolant sump . . . . . . . . . . . . . . . . . . . . 6-18

Oil the spindle brake insert . . . . . . . . . . . . . . . . . . 3-11

6-28 M-10C

LUBRICANT AND SEALANT LISTING

Product Manufacturer

Andok® “B” grease Humble Oil and Refining Company

Alvania® No. 3 grease Shell Oil Company

Cosmolube® No. 2 grease E.F. Houghton and Company

Darmex® DX-321 grease Darmex Corporation

Die Makers grease Standard Die Set Company

Mobilfluid® 350 oil Mobil Oil Corporation

Molylube® (Anti-Sieze) grease Bel Ray Company, Inc.

Nevamelt® grease Magnus Chemical

Permatex® (3D Sealer) sealant Permatex Company, Inc.

Mobil Vactra® oil No. 2 Mobil Oil Corporation

Mobil Velocite® oil No. 6 Mobil Oil Corporation

M-10C 6-29

- NOTES -

6-30 M-10C

Index

B

Bed Levers (HLV®

Machines)Removal. . . . . . . . . . . . . . . . . . . 6-1Replacement . . . . . . . . . . . . . . . . 6-9

Bed Levers (TFB®-H Machines)

Removal. . . . . . . . . . . . . . . . . . . 6-12Replacement . . . . . . . . . . . . . . . . 6-15

C

Carriage ApronDisassembly . . . . . . . . . . . . . . . . 1-1Reassembly . . . . . . . . . . . . . . . . . 1-8

Carriage HandwheelClearance adjustment. . . . . . . . . . . . 1-19Disassembly . . . . . . . . . . . . . . . . 1-17Reassembly . . . . . . . . . . . . . . . . . 1-18Removal. . . . . . . . . . . . . . . . . . . 1-17Replacement . . . . . . . . . . . . . . . . 1-18

Carriage LockRemoval. . . . . . . . . . . . . . . . . . . 1-10Replacement . . . . . . . . . . . . . . . . 1-11

Carriage LubricationDescription . . . . . . . . . . . . . . . . . 1-27Filling the reservoir . . . . . . . . . . . . . 1-33Operating the lubricator . . . . . . . . . . . 1-33Replacing a metering unit . . . . . . . . . . 1-27

Clutch Adjustment . . . . . . . . . . . . . . . . 1-10Collet Closer

Removal and cleaning . . . . . . . . . . . 4-1Replacement . . . . . . . . . . . . . . . . 4-2

Coolant FacilitiesCleaning the sump . . . . . . . . . . . . . 6-18Pump motor lubrication . . . . . . . . . . . 6-18

Cross SlideFeed screw disassembly . . . . . . . . . . 2-1Feed screw nut adjustment . . . . . . . . . 2-3Feed screw reassembly. . . . . . . . . . . 2-2Removal. . . . . . . . . . . . . . . . . . . 2-4Replacement . . . . . . . . . . . . . . . . 2-4

D

Drive BeltsAdjusting tension . . . . . . . . . . . . . . 3-2Checking tension . . . . . . . . . . . . . . 3-1Replacement . . . . . . . . . . . . . . . . 3-3

G

Gear Change BracketLubrication . . . . . . . . . . . . . . . . . 4-38

Gear Change Bracket (English)Disassembly . . . . . . . . . . . . . . . . 4-36Reassembly . . . . . . . . . . . . . . . . . 4-36

Gear Change Bracket (English-Metric)Disassembly . . . . . . . . . . . . . . . . 4-37Reassembly . . . . . . . . . . . . . . . . . 4-37

Gear RackLubrication . . . . . . . . . . . . . . . . . 1-15Removal. . . . . . . . . . . . . . . . . . . 1-12Replacement . . . . . . . . . . . . . . . . 1-14

Gearbox (English)Disassembly . . . . . . . . . . . . . . . . 4-6Lubrication . . . . . . . . . . . . . . . . . 4-2Reassembly . . . . . . . . . . . . . . . . . 4-13Removal. . . . . . . . . . . . . . . . . . . 4-3Replacement . . . . . . . . . . . . . . . . 4-16

Gearbox (English-Metric)Disassembly . . . . . . . . . . . . . . . . 4-20Lubrication . . . . . . . . . . . . . . . . . 4-18Reassembly . . . . . . . . . . . . . . . . . 4-30Removal. . . . . . . . . . . . . . . . . . . 4-19Replacement . . . . . . . . . . . . . . . . 4-35

Gib AdjustmentCarriage. . . . . . . . . . . . . . . . . . . 1-16Cross slide . . . . . . . . . . . . . . . . . 2-5Tool post slide . . . . . . . . . . . . . . . . 2-13

H

HeadstockAlignment . . . . . . . . . . . . . . . . . . 4-47Removal. . . . . . . . . . . . . . . . . . . 4-39Replacement . . . . . . . . . . . . . . . . 4-44

Headstock SpindleLubrication . . . . . . . . . . . . . . . . . 4-50Spindle lock pin . . . . . . . . . . . . . . . 4-50

L

Lead ScrewLubrication . . . . . . . . . . . . . . . . . 1-21Removal. . . . . . . . . . . . . . . . . . . 1-19Replacement . . . . . . . . . . . . . . . . 1-21

Lead Screw NutLubrication . . . . . . . . . . . . . . . . . 1-26Removal. . . . . . . . . . . . . . . . . . . 1-22Replacement . . . . . . . . . . . . . . . . 1-24

Lubricant Listing . . . . . . . . . . . . . . . . . 6-29

M-10C I-1

P

Power CaseAccessing . . . . . . . . . . . . . . . . . . 5-1Internal components (HLV

®machines) . . . 5-2

Internal components (TFB®-H machines) . . 5-4

Power Feed Control PanelSee also Power Feed DrivePower feed module . . . . . . . . . . . . . 5-6Resistor module. . . . . . . . . . . . . . . 5-7Switches . . . . . . . . . . . . . . . . . . 5-7

Power Feed DriveControl panel . . . . . . . . . . . . . . . . 3-27Disassembly . . . . . . . . . . . . . . . . 3-27Lubrication . . . . . . . . . . . . . . . . . 3-27Motor brush replacement . . . . . . . . . . 3-31Reassembly . . . . . . . . . . . . . . . . . 3-30

Preventative Maintenance Schedule . . . . . . 6-28Pulley and Shaft Assembly


S

Sealant Listing. . . . . . . . . . . . . . . . . . 6-29Speed Change Feed Screw Nut


Speed Change MechanismDisassembly . . . . . . . . . . . . . . . . 3-16Lubrication . . . . . . . . . . . . . . . . . 3-22Reassembly . . . . . . . . . . . . . . . . . 3-19Removal. . . . . . . . . . . . . . . . . . . 3-14Replacement . . . . . . . . . . . . . . . . 3-20

Spindle BrakeGap adjustment . . . . . . . . . . . . . . . 3-10Insert lubrication . . . . . . . . . . . . . . 3-11Insert replacement . . . . . . . . . . . . . 3-11

Spindle Lock PinSee Headstock Spindle

T

TailstockAlignment . . . . . . . . . . . . . . . . . . 6-25Disassembly . . . . . . . . . . . . . . . . 6-19Reassembly . . . . . . . . . . . . . . . . . 6-23

Tool Post SlideDisassembly . . . . . . . . . . . . . . . . 2-6Feed screw nut adjustment . . . . . . . . . 2-12Lubrication . . . . . . . . . . . . . . . . . 2-12Reassembly . . . . . . . . . . . . . . . . . 2-8

V

Variable Speed Control PanelOperator controls . . . . . . . . . . . . . . 5-8Switch replacement . . . . . . . . . . . . . 5-9

I-2 M-10C

- NOTES -

“Performance Has Established Leadership for Hardinge”®

Hardinge Inc.Elmira, New York 14902-1507 USA

Phone: 607-734-2281 Fax: 607-734-8819www.hardinge.com

Documents

MAINTENANCE MANUAL - Babin Machine › PDF › Hardinge HLV-H Maintenance... · 2016-05-04 · MAINTENANCE MANUAL Hardinge High Speed Super-Precision ® HLV ®-H Toolroom and TFB